MIL-HDBK-23 Structural Sandwich Composites

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MIL-YBRK-23A CHG N O T I C E 3 E 9999970 0347843 924
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c MIL-HDBK-23A
30 Dec i968
MILITARY HANDBOOK
Superseding
MIL-HDBK-23, P a r t I
ANC-23, Part II
MIL-HDBK-23, P a r t III
STRUCTURAL SANDWICH
COMPOSITES
DEPARTMENT O F DEFENSE
Washington, D.C. 20025
- -a
I
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MIL-HDBK-23A
NOTICE 3
19 June 1974
MILITARY S-TANDARDIZATION HANDBOOK
STRXTURAL SANDWICH COMPOSITES
TO ALL HOLDERS OF MIL-HDBK-23A
1. On t h e second page of t h e Table of C o n t e n t s under C h a p t e r 4 , d e l e t e t h e

e x i s t i n g page numbers and s u b s t i t u t e t h e f o l l o w i n g page numbers f o r t h e
paragraphs i n d i c a t e d :
P a r a g r a p h Number New Page Number
4.1 4-1
4.2 4 -1
4.3 4 -2
2 . D e l e t e p a g e s 4 - 1 t h r u 4-8 d a t e d 30 December 1968 and s u b s t i t u t e t h e

f o l l o w i n g pages:
N e w Pages -
Date
C o n t e n t s Page f o r 1 9 June 1974

Chapter 4
4-1 t h r u 4-5 19 June 1974
C o n t e n t s Page f o r 19 June 1974

C h a p t e r 20
20-1 t h r u 20-6 19 June 1974
3. RETAIN THIS NOTICE AND INSERT BEFORE THE TABLE OF CONTENTS.
4 . H o l d e r s of MIL-HDBK-23A w i l l v e r i f y t h a t t h e a d d i t i o n of C h a p t e r s 4 and
20 i n d i c a t e d h e r e i n h a s been e n t e r e d . T h i s n o t i c e w i l l be r e t a i n e d a s a
check sheet. T h i s i s s u a n c e i s a - s e p a r a t e p u b l i c a t i o n . Each n o t i c e i s t o
be r e t a i n e d by s t o c k i n g p o i n t s u n t i l t h e M i l i t a r y Handbook i s c o m p l e t e l y
revised o r c a n c e l l e d .
Custodians: Preparing a c t i v i t y :
Army - AV A i r Force - 11
Navy AS -
FAA P r o j e c t No, 15GP-0009
A i r Force - 11
FSC 15GP
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MIL-HDBK-23A CHG N O T I C E 3 m 7 0 0347845 7T7
MIL -HDBK-23A
NOTICE 2
24 A p r i l 1974
MILITARY STANDARDIZATION HANDBOOK
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STRUCTURAL SANDWICH COMPOSITES
TO 1 IL HOLD RS OF MIL-HDBK-23A
1. THE FOLLOWING PAGES ARE TO BE. ADDED:
NEW PAGES DATE
C o n t e n t s Page f o r
Chapter 1 9 24 A p r i l 1974
1 9 - 1 t h r u 19-7 24 A p r i l 1974
3 . Holders of MIL-HDBK-23A w i l l v e r i f y t h a t t h e a d d i t i o n of Chapter 1 9

i n d i c a t e d h e r e i n h a s been e n t e r e d . T h i s n o t i c e w i l l be r e t a i n e d a s a
check s h e e t . T h i s i s s u a n c e i s a s e p a r a t e p u b l i c a t i o n . Each n o t i c e i s
t o be r e t a i n e d by s t o c k i n g p o i n t s u n t i l t h e M i l i t a r y Handbook i s completely
revised o r cancelled.
Cus t od i a n s : Preparing a c t i v i t y :
Army -
AV A i r Force 11-
Navy -AS
FAA P r o j e c t N o . 15GP-0008
A i r Force - 11
FSC 15GP

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MIL-HDBK-23A CHG N O T I C E 3 9999970 034'7846 6 3 3
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I MIL-HDBK- 23A
NOTICE 1
9 March 1972
MILITARY STANDARDIZATION HANDBOOK
TO ALL HOLDERS OF MIL-HDBK-23A

!
I '
1. On t h e t h i r d page of t h e Table of Contents under Chapter 9 d e l e t e t h e
e x i s t i n g page numbers and s u b s t i t u t e t h e f o l l o w i n g page numbers f o r t h e
t
paragraphs i n d i c a t e d :
Paragraph No. New Page No.
9.2 9-2
9.2.1 9-5
9.3 9-8
9.4 9-8
9.5 9- 9
9.5.1 9-11
9.6 9-12
9.7 9- 12
2 . THE FOLLOWING PAGES OF MIL-HDBK-23A HAVE BEEN REVISED AND SUPERSEDE

THE PAGES LISTED:
NEW PAGES DATE SUPERSEDED DATE

PAGES
9-1 t h r u 9-13 9 Mar 1972 9-1 t h r u 9-11 30 Dec 1968
9-14 t h r u 9-39 9 Mar 1972 F i g u r e s 9-1 t h r u 30 Dec 1968

9-11 (pages
unnumbered)
2. THE FOLLOWING PAGES ARE TO BE ADDED:
NEW PAGES DATE
Contents Page f o r 9 Mar 1972

Chapter 18
18-1 t h r u 18-14 9 Mar 1972
FSC GP15

MIL-HDBK- 23A
NOTICE 1
9 March 1972
4. Holders of MIL-KDBK-23A w i l l v e r i f y t h a t page changes and additions

indicated herein have been entered. This notice w i l l be retained as a
check sheet. This issuance, together with appended pages, i s a separate
publication. Each notice i s t o be retained by stocking points u n t i l the
Military Handbook i s completely revised or cancelled.
Custodians : Preparing a c t i v i t y :
Amy AV - A i r Force 11 -
Navy AS -
FAA Project No. 1500-0097
A i r Force - 11
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MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0147848 406 W
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MIL HDB K - 2 3 A
30 Dec 1968
MIL -HDBK - 2 3 A
1. T h i s s t a n d a r d i z a t i o n handbook h a s been developed and i s being maintained

as a joint effort by t h e D e p a r t m e n t of Defense and the F e d e r a l Aviation Agency.
2. T h e i n f o r m a t i o n contained i n t h i s publication h a s been obtained f r o m n u m e r -

ous s o u r c e s , including m a t e r i a l s p r o d u c e r s , the a i r f r a m e and m i s s i l e indus -
t r y , r e p o r t s on Government-sponsored r e s e a r c h , the open l i t e r a t u r e , by con-
tract with r e s e a r c h l a b o r a t o r i e s , p a r t i c u l a r l y the U. S . F o r e s t P r o d u c t s
L a b o r a t o r y , and f r o m m e m b e r s of the MIL-HDBK-23 Working Group.
3 . E v e r y effort h a s been m a d e t o r e f l e c t the l a t e s t information on design,

f a b r i c a t i o n m e t h o d s , inspection p r o c e d u r e s , durability, and r e p a i r techniques
of sandwich c o m p o s i t e s f o r a e r o s p a c e vehicles. It is the intent to review
this handbook periodically to i n s u r e its c o m p l e t e n e s s and a c c u r a c y . U s e r s of
t h i s document a r e encouraged t o r e p o r t any e r r o r s d i s c o v e r e d and r e c o m -
mendations for changes o r inclusions to A i r F o r c e Flight Dynamics L a b o r a -
t o r y , S t r u c t u r e s Division (FDTS), W r i g h t - P a t t e r s o n A i r F o r c e B a s e , Ohio,
45433.
DEPARTMENT O F DEFENSE
Washington, D. C. 20025
Custodians : P r e p a r i n g activity:
Army A V - Air Force 11 -
Navy AS -
FAA P r o j e c t No. 1500-0072
Air Force - 11
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MIL-HDBK-23A CHG N O T I C E 3 9999970 0347849 3 4 2 M
MIL-HDBK-2 3A
30 Dec 1968
CONT EN TS
CHAPTER 1--INTRODUCTION
Page
1. Scope. ................... 0 0 0 0 . 0 1-1

.. . .. ...
1.2 B a s i c Design P r i n c i p l e s 1-2
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. * * o 0 0
. .......
o e e e o
1.3 Fundamental F o r m u l a s o e e 0 0 a 1-4

1.3.1 Sandwich Bending Stiffness o . . 0 . . 0 0 0 1-5
....
o e o
1.3.2 Sandwich Extensional Stiffness e a s . 0 0 . 1-6

1 . 3 . 3 S a n d w i c h s h e a r Stiffness e e o ... e e . . e O D 0 1-6
CHAPTER 2--MATERIALS
2.1 Facing M a t e r i a l s . .... . e e e e ...... ... o o 2-1

2 . 1 . 1 Functions, D e s c r i p t i o n s , Usual F o r m s . . 2-1
......... . .. ....
e e a e e
2.2 Sandwich C o r e s 2 -3
. . ....
e o e e
2.2.1 Description of C o r e s . o . . . o o o o o 2 -3
2 . 2 . 2 M e c h a n i c a l P r o p e r t i e s of C o r e s . e . .. . 2-10
...... .. -
o o e
2.3Adhesives. . . 2-17
. . .... .. ...
e e e o e a e o o
2.3.1 Types 2-18

. ..
o o e o o e e
2.3.2 Available S o u r c e s . . .. 2 -24

....
o o
e o o o e
2.3.3 F o r m s . s e e e o 2 -24
. . ..
O . O . e O O O . . O a
2 . 3 . 4 S t o r a g e and Mixing of Adhesives , 2-25

.. . . .
o o o o o
2.3.5 Strength of Adhesive Bonds o o o o o o e e 2 -26
'
, CHAPTER 3--WRINKLING O F SANDWICH FACINGS
UNDER EDGEWISE LOAD
3.1 B a s i c P r i n c i p l e s . e o.. e o .o a a e o . . . e e e e 3-1

3 -2
3.2 Sandwich with C o r e Supporting Facings Continuously
... .. . . .
e e o e a
3.3 S a n d w i c h w i t h H o n e y c o m b C o r e s . o e e e 3 -4
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MIL-HDBK-23A C H G N O T I C E 3 W 9 9 9 9 9 7 0 014750 Ob4
CHAPTER 4--DIMPLING O F SANDWICH FACINGS

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UNDER EDGEWISE LOAD
4.1 Basic Principles. ............... 4-1

. .
e . 0 0 .
4.2 Sandwich Having C e l l u l a r (Honeycomb) C o r e 4-1

. . . .....
o 0 . 0 0 0
4 . 3 Sandwich Having C o r r u g a t e d C o r e e e o e e 4 -2
CHAPTER 5--DESIGN O F F L A T RECTANGULAR S, NDWICH P. r ELS

I
UNDER EDGEWISE COMPRESSION LOAD
5.1 B a s i c P r i n c i p l e s . .................... 5-1

5.2 Determining F a c i n g Thickness .............. 5-1
5.3 Determining C o r e Thickness and C o r e S h e a r Modulus e .
e a 5 -2
5.3.1 Determination of Minimum Values of h ....... 5 -4
5.3.2 Determination of Actual Values of h. ........ 5 -6 .~
5.3.3 Checking P r o c e d u r e f o r Determining Buckling S t r e s s ,

F
cr
..................... 5 -7
CHAPTER 6 . --DESIGN O F F L A T RECTANGULAR SANDWICH PANELS
UNDER EDGEWISE SHEAR LOAD
6.1 Basic Principles. .................... 6-1

6 . 2 Determining F a c i n g T h i c k n e s s .............. 6-1
6.3 Determining C o r e T h i c k n e s s and C o r e S h e a r Modulus . . e o o -2
6 . 3 . 1 .Determination of Minimum Values of h . . . . . . . 6 -4
6.3.2 Determination of Actual Values of h . . . . . . . . . 6 -6
6.3.3 Checking P r o c e d u r e of Determining Buckling S t r e s s ,
F
cr
..................... 6 -7
CHAPTER 7--DESIGN O F F L A T RECTANGULAR SANDWICH PANELS
UNDER EDGEWISE BENDING MOMENT
7.1 B a s i c P r i n c i p l e s . .................... 7-1

7.2 Determining F a c i n g T h i c k n e s s .............. 7-1
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7 . 3 Determining C o r e T h i c k n e s s and C o r e S h e a r Modulus o 7 -3
........
7 . 3 . 1 Determination of Minimum Values of h 7 -5
7.3.2 ..
Determination of Actual Values of h . . e o e 7 -5
7 . 3 . 3 Checking P r o c e d u r e f o r Determining Buckling S t r e s s ,
F
cr
...................... 7 -6
CHAPTER 8--DESIGN O F F L A T RECTANGULAR SANDWICH PANELS
UNDER COMBINED LOADS
8. 1 Basic P r i n c i p k s .................... 8-1

8.2 Biaxial Compression. .................. 8 -2
8.3 Bending and C o m p r e s s i o n e. . . . . 8 -2
. - .. ..
a a o o o a a e o a
8*4 . .
C o m p r e s s i o n and S h e a r o. o o a e e o 8-2
8.5 Bending a n d s h e a r . ................... 8-2
8.6 Edge Loads Combined with N o r m a l Loads ......... 8-3
CHAPTER 9--DESIGN O F F L A T SANDWICH PANELS

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UNDER UNIFORMLY DISTRIBUTED NORMAL LOAD
9. 1 B a s i c P r i n c i p l e s .................... 9-1
9 . 2 Determining F a c i n g T h i c k n e s s , C o r e T h i c k n e s s , and C o r e
S h c a r Modulus f o r Simply Supported F l a t R e c t a n g u l a r
Pancxls ....................... 9-1
...............
9 . 2 . 1 Use of Design C h a r t s 9 -4
..............
9 . 3 Determine Core Shear S t r e s s . 9 -6
9 . 4 Checking P r o c e d u r e ................... 9 -6
9 . 5 Determining F a c i n g T h i c k n e s s , C o r e T h i c k n e s s , and C o r e
S h e a r Modulus f o r Simply Supported Flat C i r c u l a r P a n e l s . 9 -7
...............
9 . 5 . 1 U s e of Design C h a r t s 9 -9
9.6 Determine Core Shear S t r e s s . .............. 9-10
9.7 Checking P r o c e d u r e ................... 9-10

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CHAPTER 10--DESIGN O F SANDWICH CYLINDERS
UNDER EXTERNAL RADIAL PRESSURE
10.1 Basic Principles. ................... 10-1

10.2 De te rmining Facing T h i c k n e s s , C o r e T h i c k n e s s , and C o r e
S h e a r Modulus f o r Sandwich Cylinde rs Under Exte r n a l
Radial P r e s s u r e .................. 10-2
10.2. 1 Determination of Minimum Values of h ...... 10-4
10.3 F i n a l Design ..................... 10-4 I
CHAPTER 11 --DESIGN O F SANDWICH t
CYLINDERS UNDER TORSION
11.1 B a s i c P r i n c i p l e s . ................... 11-1

11.2 Determining Facing T h i c k n e s s . ............. 11-2
...
11.3 Determining C o r e T h i c k n e s s and C o r e S h e a r Modulus 11-3 _-
11.3.1 Determination of Minimum Values of d ...... 11 -4

11.3.2 Determination of Actual Values of d ....... 11-5
11.3.3 Checking P r o c e d u r e f o r Determining Buckling
Stress, F
scr
................ 11-6
11.4 Check t o Determine Whether Sideways Buckling W i l l O c c u r . 11 -6

UNDER AXIAL COMPRESSION OR BENDING
12.1 Basic Principles. ................... 12-1

12.2 Determining Facing Thickne s se s ............ 12-1
12.3 Determining C o r e T h i c k n e s s and C o r e S h e a r Modulus . . . 12-2
12.4 Checking P r o c e d u r e f o r Determining Cylinder Wall Buckling
Stress, F
cr
.................... 12 -7
12-5 Check t o Determine Whether Column Buckling W i l l O c c u r . 12-7

r-
12.1 B a s i c P r i n c i p l e s . ................. . . 13-1

..
1 2 * 2 Axial C o m p r e s s i o n and E x t e r n a l L a t e r a l P r e s s u r e . . 13-2
...........
1 3 . 3 Axial C o m p r e s s i o n and T o r s i o n . . 13 -2
..
13.4 Torsion and Lateral External o r I n t e r n a l P r e s s u r e . . 13-2 -
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CHAPTER 14--FABRICATION
14.1 F a b r i c a t i o n of C o r e s . ................. 14- 1

14.1.1 P r e p a r a t i o n f o r U s e .............. 14-1
14.2 F a b r i c a t i o n of Bonded Construction ........... 14-5
14.2.1 P r e p a r a t i o n f o r Bonding. ............ 14-6
14.2.2 Method of Applying Adhesives
14.3 B r a z e d o r Welded Sandwich Construction.
. . .. .. .. .. .. .. .. .. 14- 14
14-20
14.4 Sandwich P r o d u c t i o n Techniques ............ 14-2 1
14.4.1 Means of Applying P r e s s u r e . .......... 14-22
14.4.2 Techniques for Curved P a r t s .......... 14-30
14.4.3 Mold-Release A g e n t s . ............. 14-32
14.4.4 Attachment Details ............... 14-34
14.4.5 T r i m m i n g . .................. 14-36
14.4.6 Safety P r e c a u t i o n s ............... 14-36
14.4.7 Specifications ................. 14-37
CHAPTER 15--INSPECTION A N D TEST METHODS
15.1 Inspection of Raw M a t e r i a l s .............. 15-1

15.1.1 C o r e s . . . . . . . ............. 15-2
15.1.2 F a c i n g s . . . . . . . ............. 15-2
1 5 . 1 . 3 Adhesives and R e s i n s . . . . . . . . . . . . . . 15-2
15.2 Inspection of Completed P a r t s . . . . . . . . . . . . . 15-4
15.2.1 Visual Inspection. . . . . . . . . . . . . . . . 15-4
15.2.2 T a p p i n g . . . . . . . . . . . . . . . . . . . . 15-5
15.2.3 S p u r Wheel . . . . . . . . . . . . . . . . . . 15-6
15.2.4 U l t r a s o n i c I n s p e c t i o n . . . . . . . . . . . . . . 15-6
15.2.5 Radiographic Inspection. . . . . . . . . . . . . 15-6
'15.2.6 Vibrator - Amplifier Inspection . . . . . . . . . 15-6
15.2.7 T h e r m o g r a p h i c Inspection. . . . . . . . . . . . 15-7
15.3 P r o o f Loading D e v i c e s . . . . . . . . . . . . . . . . . 15-7
15.3.1 E x p o s u r e to Vacuum . . . . . . . . . . . . . . 15-7
15.3.2 Vacuum-Induced Concentrated Load T e s t e r . . . . 15-8
15.3.3 Multiple Proof L o a d e r . . . . . . . . . . . . . 15-8
15.4 Specifications .................... 15-9
15.5 T e s t Methods . . . . . . . . . . . . . . . . . . . . . 15-10
15.5.1 T e s t Methods f o r C o r e M a t e r i a l s . . . . . . . . 15-10
15.5.2 T e s t Methods f o r Adhesives and f o r Bonded J o i n t s . 15-10
15.5.3 Lap-Joint Metal-to-Metal S h e a r T e s t . . . . . . . 15-10
15.5.4' Lap-Joint S h e a r T e s t at Various T e m p e r a t u r e s . . 15-12
1 5 . 5 . 5 Lap-Joint S h e a r T e s t After E x p o s u r e . . . . . . . 15-13
15.5.6 Lap-Joint Specimens in Fatigue T e s t i n g . . . . . 15-13 -
15.5.7 Use of Lap-Joint S p e c i m e n s in L o n g - T i m e Loading. 15-13
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MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 7 7 0 01478.54 7 0 T
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CHAPTER 16 --REPAIR
1 6 . 1 General. o
e o e
e . .... a ... . . e 16-1
1 6 . 2 P r i n c i p l e s of Repair . , . ... 16-1
. . . . . ..
e e o e e e a e o
1 6 . 3 C l a s s e s of R e p a i r 16-3
......
o e o o e e eo e o
1 6 . 4 R e p a i r of P l a s t i c Sandwich P a r t s ( r e f . 1 6 - 1 ) . 16 -4
16.4.1 Repair Materials. . .... . .. 16 -4
. . .
e o o e o o
16.4.2 P r e p a r i n g Parts for Repair . .. 16-5

.. ....
o e ee a
1 6 . 4 . 3 R e p a i r Techniques . ... 16-6

.... ..
e a e o
1 6 . 4 . 4 S p e c i a l Considerations o . . 16-10
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e o e e
1 6 . 5 R e p a i r of Adhesive-Bonded M e t a l Sandwich ( r e f . 1 6 - 2 ) . . . 16-11

1 6 . 5 . 1 Repair Materials e . .... . . .. 16-11
. ..
o o
1 6 . 5 . 2 R e p a i r Techniques . . .. 16-13
. . ..
e o e a a e
16.6 R e p a i r of B r a z e d o r Welded Sandwich . . . 16-23

. . ..
o e e
1 6 . 6 . 1 Adhesive Injection R e p a i r s . . . 16 - 2 3
.
o e a
16.6.2 Potting Repairs e o e o e . . o . o e ... 16 -26

16.6.3 Brazed Patch Repair o e e . o e a e ... 16-26
CHAPTER 17 --DURABILITY
17.1 General. ........ .. e o ... .. e ..... 17-1

1 7 , 1. 1 E n v i r o n m e n t a l E x p o s u r e of Adhesive-Bonded J o i n t s 17-1
1 7 . 1 . 2 E n v i r o n m e n t a l Evaluation of Sandwich
Constructions ...... , ........
e 17 -2
17.2 Rain E r o s i o n of P l a s t i c Leading Edges , ... . ..... 17 - 4

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MIL-HDBK-23A C H G N O T I C E 3 M 9999970 0147855 646

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MIL-HDBK -23A
30 Dec 1968
NOTATION
T h e following notation is u s e d throughout t h e Handbook. Additionally,

portions of the Handbook devoted t o a p a r t i c u l a r component define the s y m -
b o l s u s e d f o r the f i r s t time i n t h a t portion. An occasional symbol not in
g e n e r a l u s e w i l l a p p e a r i n s p e c i f i c a r e a s and not be included in this notation.
F i g u r e 1 - 2 shows notation f o r sandxvich construction.
Units of d i m e n s i o n s , f o r c e s , s t r e s s e s , c o n s t a n t s , and other quantities

a r e not specified u n l e s s they a r e employed i n f o r m u l a s xvherein n u m e r i c a l
coefficients a r e not non-dimensional. In applying f o r m u l a s f o r u.hich units
a r e not s p e c i f i e d , c o r r e c t r e s u l t s will not be obtained u n l e s s u n i t s a r e con-
s i s t e n t - - f o r example: If t h i c k n e s s e s a r e given in inches and f o r c e s in
pounds, then the length and xvidth of a panel m u s t b e i n inches (not feet) to
give s t r e s s e s i n pounds p e r s q u a r e inch.
1 - Subscript denoting facing 1 of a sandwich

2 - Subscript denoting facing 2 of a sandwich
a , b - Length of panel edge; s u b s c r i p t s denoting p a r a l l e l t o a o r b edge
B - S u b s c r i p t denoting bond o r bending
C - Subscript denoting c o r e o r c o m p r e s s i o n
c r - S u b s c r i p t denoting c r i t i c a l
D - Bending s t i f f n e s s o r twisting s t i f f n e s s depending on s u b s c r i p t s
d - Total sandwich depth o r thickness - . - I _
E - Y o u n g ' s modulus of e l a s t i c i t y ; for orthotropic facing E = V E E

a b .-
E ' - Effective modulus of e l a s t i c i t y ; for orthotropic facings E ' - E E.
= \ a b
F - Allowable s t r e s s ; s u b s c r i p t denoting facings when applied to buckling
coefficients
G e o m e t r i c view f a c t o r between sandwich facings
=12 -
f - Calculated s t r e s s
G - Modulus of rigidity; with s u b s c r i p t s G is t h e modulus of rigidity
ab
a s s o c i a t e d with s h e a r d i s t o r t i o n of t h e a b plane
G' - Effective modulus of rigidity
H - Extensional s t i f f n e s s
h - Distance between facing c e n t r o i d s
K - A coefficient
L - Length, c o r e a x i s ( s e e c h a p t e r 2 f o r d e t a i l s )
M - Bending m o m e n t ; s u b s c r i p t denoting behavior of sandwich with thin
facings when applied t o buckling coefficients.
m - Half width of c o r r u g a t i o n o r number of half waves
N - Load p e r unit length of edge
n - Number of half waves
0 - Subscript denoting V = O .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

0 - S u b s c r i p t denoting honeycomb c o r e ribbon o r c o r e c o r r u g a t i o n s h e e t
P - Load
P - Intensity of d i s t r i b u t e d load
r - Radius; s u b s c r i p t denoting r e d u c e d
R - Ratio
s - S h e a r load n o r m a l t o s u r f a c e of panel
S -C o r e c e l l s i z e ; s u b s c r i p t denoting s h e a r when applied to s t r e s s and
s e c a n t when applied to moduli
T - T o r q u e ; c o r e axis (see c h a p t e r 2 f o r d e t a i l s ) ; facing d i s s i m i l a r i t y
1
index T =
1+-
1
T - Mean t e m p e r a t u r e
m
t T h i c k n e s s ; without s u b s c r i p t denotes facing thicknes s ; s ubs c r ipt
denoting tangent when applied to moduli
U T r a n sver s e s h e a r stiffness
U S u b s c r i p t t o s t r e s s denoting ultimate
V P a r a m e t e r r e l a t i n g s h e a r and bending stiffness
W Weight; c o r e axis ( s e e c h a p t e r 2 f o r d e t a i l s ) s p e c i a l p a r a m e t e r r e l a t i n g
s h e a r 2nd bending s t i f f n e s s f o r sandwich with c o r r u g a t e d c o r e
W Density; s u b s c r i p t denoting wrinkling
X Axis; s u b s c r i p t denoting p a r a l l e l t o x - a x i s
Y A x i s p e r p e n d i c u l a r t o x - a x i s ; s u b s c r i p t denoting p a r a l l e l t o y - a x i s ;
o r denoting yield when applied t o s t r e s s
z A x i s n o r m a l to s u r f a c e of sandwich; s u b s c r i p t denoting p a r a l l e l to
z-axis
(Y ~ E ; / Ea
B
AG!
ba
Y Shear s t r a i n ; elastic property parameter y =
6 Deflection
E C o m p r e s s i o n o r extension s t r a i n ; e m i s s i v i t y
1 P l a s t i c i t y coefficient; convective heat t r a n s f e r coefficient
h One m i n u s the product of two P o i s s o n s r a t i o s X = 1 t~ p
ab ba
-
v P o i s s o n s r a t i o ; with s u b s c r i p t s t~
ab
i s t h e r a t i o of c o n t r a c t i o n in t h e
b d i r e c t i o n to extension i n t h e a d i r e c t i o n due t o a t e n s i l e s t r e s s i n
the a direction.
Radius of g y r a t i o n _.~
P
0- Stefan -Boltzmann constant
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

flIb-HDBK-23A C H G N O T I C E 3 m 9999970 0347857 4 3 9 m
1
Conversion of U.S. Customary U n i t s t o SI Units-
: lbrn/in. : 27.68 x lo3: k i l o g r a m s / m e t e r 3 (kg/m3)

3,
Density : 16.02 : kilograms / m e t e r ( k g / m
: O. 3048 : m e t e r s (m)
Length : in. : 0.0254 : m e t e r s (m)
L.
Stress : psi : 6.895 x l o 3 : n e w t o n s / m e t e r 2 ( N / m 2 )
Pres s u r e (i
L.
: lb/in.
lb/ft2
: 6.895 x l o 3 : n e w t o n s / m e t e r 2 ( N / m 2 )
: 47.88 : newtons / m e t e r 2 ( N / m 2 )
Elasticity 1 psi : 6.895 x l o 3 : n e w t o n s / m e t e r 2 ( N / m 2 )
Temper ature : (OF t 460) : 5/9 : d e g r e e s Kelvin

. . ,- - -,
("KI
T h e r m a l conductivity : Btu in. / h r f t 2 " F : O . 1240 : kg c a l / h r m OC
P r e f i x e s t o indicate multiples of units are as follows:
-
Prefix : Multiple
(GI
gigs .
: lo9
6
mega(M) : 10
kilo (k) : lo3
milli (m) :
-6
m i c r o (p) : 10
1
-The International System of Units [Systeme International (SI)] w a s adopted by the
Eleventh General Conference on Weights and M e a s u r e s , P a r i s , Oct. 1960, i n
Resolution No. 12.
2
-Multiply value given i n U.S. C u s t o m a r y Unit by conversion factor t o obtain
equivalent value i n SI unit.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 m 9997770 0147858 355 m
MIL -HDBK- 2 3A
30 Dec 1968
CHAPTER 1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
INTRODUCTION
1.1 S C O P E
Military Handbook 23 h a s b e e n p r e p a r e d f o r use i n t h e design of s t r u c -

t u r a l sandwich c o m p o s i t e s , p r i m a r i l y f o r flight vehicles. Information p r e -
sei-ited includes d e s i g n p r o c e d u r e s , f a b r i c a t i o n m z t h o d s , inspection p r o -
c d u r e u , and r e p a i r techniques f o r bi>th m i l i t a r y and c o m m e r c i a l vehicles.
Methods and p r o c e d u r e s other than t h o s e given h e r e i n a r e a l s o a c c e p t a b l e ,
provided they give c o m p a r a b l e r e s u l t s o r a r e p r o p e r l y substantiated. T h i s
Handb3ok r e p l a c e s t h e s e v e r a l p a r t s previously published as t h e ANC-23
Bulletin, and m o r e r e c e n t l y as Parts I and III of M i l i t a r y Handbook 23.
S t r u c t u r a l d e s i g n information is p r e s e n t e d i n a f o r m for r a p i d c a l c u l a -
tion f o r sandwich construction. F o r m u l a s and c h a r t s f o r the solution of t h e
f o r m u l a s a r e given f o r t h e i n i t i a l d e s i g n of sandwich components. T h e
c h a r t s a r e e n t e r e d with p a r a m e t e r s based on dimensions and m a t e r i a l p r o p -
e r t i e s . Check of d e s i g n s c a n be made with f o r m u l a s and c u r v e s p r e s e n t e d
,
f o r v a r i o u s components, L i m i t a t i o n s of f o r m u l a s and c h a r t s a r e indicated

and r e f e r e n c e is m a d e t o m o r e detailed a n a l y s e s p r e s e n t e d i n other
publications.
T h e d e s i g n p r o c e d u r e s a r e based principally on a n a l y s e s and t e s t s p e r -

f o r m e d by t h e U . S . F o r e s t P r o d u c t s L a b o r a t o r y under t h e s p o n s o r s h i p of
t h e MIL-HDBK-23 Working Group on S t r u c t u r a l Sandwich Composites f o r
A e r o s p a c e Vehicles ( f o r m e r l y ANC-23 P a n e l ) .
1-1

MIL-HDBK-23A CHG NOTICE 3 9 9 9 9 9 7 0 Ol147859 2 9 1
1. 2 BASIC DESIGN PRINCIPLES
S t r u c t u r a l sandwich is a l a y e r e d composite f o r m e d by bonding two

thin facings t o a thick c o r e . It is a type of s t r e s s e d - s k i n construction i n
which the facings r e s i s t n e a r l y all of the applied edgewise (in-plane) loads
and flatwise bending m o m e n t s . The thin s p a c e d facings provide n e a r l y all
of the bending rigidity t o the construction. The c o r e s p a c e s the facings and
t r a n s m i t s s h e a r between t h e m s o that they a r e effective about a common
n e u t r a l axis. T h e c o r e a l s o provides m o s t of the s h e a r rigidity of the s a n d -
wichconstruction. By p r o p e r choice of materials for facings and c o r e ,
constructions with high r a t i o s of stiffness to weight can be achieved.
A b a s i c d e s i g n concept is t o s p a c e s t r o n g , thin facings f a r enough a p a r t

t o achieve a high r a t i o of s t i f f n e s s to weight; the lightweight c o r e that does
this a l s o provides the r e q u i r e d r e s i s t a n c e to s h e a r and is s t r o n g enough to
s t a b i l i z e the facings t o t h e i r d e s i r e d configuration through a bonding m e d i u m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
s u c h as a n adhesive l a y e r , b r a z e , o r weld. T h e sandwich i s analogous to an
I - b e a m i n which t h e flanges c a r r y d i r e c t c o m p r e s s i o n and tension l o a d s , a s
do the sandwich f a c i n g s , and the web c a r r i e s s h e a r l o a d s , as does the s a n d -
wich c o r e .
In o r d e r that sandwich c o r e s be lightweight, they a r e usually m a d e of

low -density m a t e r i a l , s o m e type of c e l l u l a r construction (honeycomb-like
c o r e f o r m e d of thin s h e e t m a t e r i a l ) , o r of c o r r u g a t e d s h e e t m a t e r i a l . A s a
consequence of employing a lightweight c o r e , d e s i g n methods account f o r
c o r e s h e a r d e f o r m a t i o n because of the low effective s h e a r modulus of the
c o r e . T h e m a i n difference i n d e s i g n p r o c e d u r e s f o r sandwich s t r u c t u r a l
e l e m e n t s as c o m p a r e d to d e s i g n p r o c e d u r e s for homogeneous m a t e r i a l i s
the inclusion of the effects of c o r e s h e a r p r o p e r t i e s on deflection, buckling,
and s t r e s s f o r the sandwich.
B e c a u s e thin facings can be used to c a r r y loads in sandwich, p r e v e n -

tion of l o c a l f a i l u r e under edgewise d i r e c t o r flatwise bending loads is n e c - 4
e s s a r y j u s t as prevention of l o c a l crippling of s t r i n g e r s is n e c e s s a r y i n the
d e s i g n of s h e e t - s t r i n g e r construction. Modes of f a i l u r e that m a y occur i n
sandwich under edge load a r e shown i n f i g u r e 1-1.
S h e a r c r i m p i n g f a i l u r e (fig. 1-1B) a p p e a r s t o be a l o c a l mode of failure,

but i 6 actually a f o r m of g e n e r a l o v e r a l l buckling (fig. 1-1A) i n which t h e
wavelength of the buckles is v e r y s m a l l b e c a u s e of low c o r e s h e a r modulus.
The c r i m p i n g of t h e sandwich o c c u r s suddenly and usually c a u s e s the c o r e
t o fail i n s h e a r at the c r i m p ; i t m a y a l s o c a u s e s h e a r f a i l u r e i n t h e bond
between the facing and c o r e .

-_
--
MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 7 8 6 0 T O 3
C r i m p i n g m a y a l s o o c c u r i n c a s e s w h e r e the o v e r a l l buckle begins to

a p p e a r and then t h e c r i m p o c c u r s suddenly b e c a u s e of s e v e r e l o c a l s h e a r
s t r e s s e s at the ends of the o v e r a l l buckle. As soon as the c r i m p a p p e a r s ,
the o v e r a l l buckle m a y d i s a p p e a r . T h e r e f o r e , although examination of the
failed sandwich indicates c r i m p i n g o r s h e a r instability, f a i l u r e m a y have
begun by o v e r a l l buckling that finally c a u s e d crimping.
If the c o r e i s of c e l l u l a r (honeycomb) o r c o r r u g a t e d m a t e r i a l , i t i s p o s -
s i b l e f o r the facings to buckle o r dimple into the s p a c e s between c o r e w a l l s
o r c o r r u g a t i o n s as shown i n f i g u r e 1-1C. Dimpling m a y be s e v e r e enough
s o that p e r m a n e n t d i m p l e s r e m a i n a f t e r r e m o v a l of load and the amplitude
of t h e d i m p l e s m a y be l a r g e enough t o c a u s e the d i m p l e s t o grow a c r o s s the
c o r e c e l l w a l l s and r e s u l t in a wrinkling of the facings.
Wrinkling, as shown i n figure 1 - l D , may o c c u r i f a sandwich facing s u b -

j e c t e d to edgewise c o m p r e s s i o n buckles as a plate on an e l a s t i c foundation.
The facing m a y buckle i n w a r d o r outward, depending on the flatwise c o m -
p r e s s i v e s t r e n g t h of the c o r e r e l a t i v e t o t h e flatwise t e n s i l e s t r e n g t h of the
bond between t h e facing and c o r e . If the bond between facing and c o r e is
s t r o n g , facings can wrinkle and c a u s e t e n s i o n f a i l u r e i n the c o r e . T h u s , the
wrinkling load depends upon the e l a s t i c i t y and s t r e n g t h of the foundation
s y s t e m ; namely, the c o r e and the bond between facing and c o r e . Since the
facing is never perfectly flat, the wrinkling load w i l l a l s o depend upon the
initial e c c e n t r i c i t y of the facing o r o r i g i n a l waviness.
T h e l o c a l m o d e s of failure may o c c u r i n sandwich panels under edgewise

l o a d s o r n o r m a l l o a d s . In addition t o o v e r a l l buckling and l o c a l modes of
f a i l u r e , sandwich is designed s o that facings do not f a i l i n t e n s i o n , c o m -
p r e s s i o n , s h e a r , o r combined s t r e s s e s due t o edgewise loads o r n o r m a l
l o a d s , and c o r e s and bonds do not fail i n s h e a r , flatwise tension, o r f l a t -
w i s e c o m p r e s s i o n due to n o r m a l loads.
The b a s i c design principles c a n be s u m m a r i z e d into four conditions as

follows :
1. Sandwich facings s h a l l be a t l e a s t thick enough to withstand chosen

1
design s t r e s s e s u n d e r design- loads.
2. The c o r e s h a l l b e thick enough and have sufficient s h e a r rigidity and

s t r e n g t h s o that o v e r a l l sandwich buckling, e x c e s s i v e deflection, and s h e a r
f a i l u r e will not o c c u r u n d e r design-1 loads.
1
-Design load s h a l l be "design u l t i m a t e load" when composite s t r u c t u r e s a r e
to b e designed f o r u s e i n m i l i t a r y a i r c r a f t w h e r e the r e q u i r e m e n t s of
M i l i t a r y Specification MIL-S-8698 and s e r i e s MIL-A-8860 through
MIL-A-8870 a r e applicable,
1-3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
_-
L. --
NIL-HBBM-23A
~
CHG N O T I C E 3 = qqqqq70 oIdudb1 74T =

%
c 3. The c o r e s h a l l have high enough moduli of e l a s t i c i t y , and the sandwich
s h a l l have g r e a t enough flatwise t e n s i l e and c o m p r e s s i v e s t r e n g t h s o that
wrinkling of e i t h e r facing will not o c c u r under design-1 loads.
4. If the c o r e i s c e l l u l a r (honeycomb) o r of c o r r u g a t e d m a t e r i a l and

dimpling of the facings is not p e r m i s s i b l e , the c e l l s i z e o r corrugation
spacing s h a l l b e s m a l l enough s o t h a t dimpling of e i t h e r facing into the c o r e
s p a c e s will not o c c u r u n d e r design-1 loads.
The choice of m a t e r i a l s , methods of sandwich a s s e m b l y , and m a t e r i a l

p r o p e r t i e s u s e d f o r design s h a l l be compatible with the expected environ-
m e n t in which the sandwich i s to be utilized. F o r e x a m p l e , facing to c o r e
bonding s h a l l have sufficient flatwise tensile and s h e a r s t r e n g t h to develop
the required sandwich panel s t r e n g t h i n the expected environment. Included
as environment a r e effects of t e m p e r a t u r e , w a t e r o r m o i s t u r e , c o r r o s i v e
a t m o s p h e r e and fluids, fatigue, c r e e p , and any condition that m a y affect
material properties.
Certain additional c h a r a c t e r i s t i c s , s u c h as t h e r m a l conductivity,

r e s i s t a n c e to s u r f a c e a b r a s i o n , dimensional stability, p e r m e a b i l i t y , and
e l e c t r i c a l p r o p e r t i e s of the sandwich m a t e r i a l s should be considered in
a r r i v i n g a t a thoroughly efficient design f o r the intended purpose. --
Detailed p r o c e d u r e s giving f o r m u l a s and graphs f o r u s e in s t r u c t u r a l

design a r e given i n subsequent sections of this Handbook. The f o r m u l a s
and graphs can be u s e d to d e t e r m i n e dimensions of facings and c o r e a s well
a s n e c e s s a r y c o r e p r o p e r t i e s f o r sandwich components u n d e r v a r i o u s types
of loads. G r a p h s and f o r m u l a s a r e p r e s e n t e d in t e r m s of g e n e r a l p a r a m -
e t e r s , and a r e not for specific m a t e r i a l s . Design p r o c e d u r e s involving
buckling a r e b a s e d on t h e o r e t i c a l buckling coefficients. T h e s e coefficients
a r e in fair a g r e e m e n t with a v e r a g e t e s t r e s u l t s , but allowance can be m a d e
in t h e final design to account f o r the s c a t t e r c h a r a c t e r i s t i c of buckling t e s t
r e s u l t s , perhaps by choosing a slightly thicker c o r e , s o that buckling of
the sandwich component does not o c c u r a t design load.
1.3 FUNDAMENTAL FORMULAS
In the development of f o r m u l a s f o r deflection, s t r e s s e s , and buckling of

sandwich components, m a t h e m a t i c a l e x p r e s s i o n s f o r bending, extensional,
and shear s t i f f n e s s often a p p e a r as do p a r a m e t e r s involving t h e s e s t i f f n e s s e s .
It i s convenient to p r e s e n t the fundamental stiffness f o r m u l a s a t the o u t s e t .
H e r e a l s o a r e d i s c u s s e d the effects of facing and c o r e stiffness on sandwich
bending stiffness s o that the d e g r e e of approximation implied by simplified
f o r m u l a s neglecting facing and c o r e stiffness i s known,
1-4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
J --
No reproduction or networking permitted without license from IHS Not for Resale, 09/27/2006 07:13:23 MDT i6-
--- __
MIL-HDBK-23A CHG N O T I C E 3 7999970 O347862 886
1 . 3 . 1 Sandwich Bending Stiffness
A s t r u c t u r a l sandwich u n d e r f o r c e s n o r m a l to i t s facings has a bending

s t i f f n e s s , p e r unit width, given by the f o r m u l a
E't E't E't

1 1 c c
D =
E't E't ' A
2 2 h +- -
* A
-
.1 1 +-+-c c
A A
2 C
1 C
E't
E2t2
- c c
- (1:l)
J L
w h e r e E ' is the effective modulus of e l a s t i c i t y of facing; E ! is effvctivc
C
c o r e e l a s t i c modulus i n the a p p r o p r i a t e L o r W directiori:::--not thr. T d i r e c -
t i o n - - ( s e e c h a p t e r 2 f o r d e t a i l s ) ; X i s one minus the product of txvo P o i s s o n ' c
r a t i o s (A = 1 - p p ); t i s facing t h i c k n e s s ; 1 and 2 a r e s u b s c r i p t s dcnoting
ab ba
facing 1 and 2 ; t i s c o r e t h i c k n e s s ; and h i s d i s t a n c e between facing c e n -
C
t r o i d s . (See s k e t c h of f i g u r e 1 - 2 f o r notation. ) F o r many combinations of
facing m a t e r i a l s i t will be found advantageous t o choose t h i c k n e s s e s such
that E t = E t
1 1 2 2'
F o r sandwich with facings of the s a m e m a t e r i a l and t h i c k n e s s . formula
( 1 : l ) r e d u c e s to
(1:ia)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
which can a l s o be Lvritten a s
E ' th'
D=K- (1:lb)
2X
The s e c o n d t e r m of f o r m u l a ( 1 : l a ) i n c o r p o r a t i n g facing s t i f f n e s s and c o r e

s t i f f n e s s i s neglected f o r m o s t sandLvich. The effect of this second t e r m in
i n c r e a s i n g b a s i c sandxvich s t i f f n e s s i s obtained f r o m values of K ( f o r m u l a
1 : l b ) shown g r a p h i c a l l y i n f i g u r e 1 - 3 .
+ F o r honeycomb c o r e s t h e e l a s t i c moduli (not s h e a r moduli) p a r a l l e l and
p e r p e n d i c u l a r t o the c o r e ribbon ( L o r W d i r e c t i o n ) a r e e s s e n t i a l l y z e r o .
1-5

L ~~
~.
MIL-HDBK-23A CHG N O T I C E 3 M 7777770 0347863 732
If t h e sandwich h a s thin facings o n a c o r e of negligible bending s t i f f n e s s ,

as is usually t h e c a s e , and a f t e r a s s u m i n g h = h 2 = h , t h e bending s t i f f n e s s
1
i s given by the f o r m u l a : -I
D = (1:2)
2
E' t h
D= (for e q u d facings) (1:2a)
2h
1 . 3 . 2 Sandwich E x t e n s i o n a l Stiffness
T h e extensional s t i f f n e s s of a sandwich, s t r e t c h e d o r c o m p r e s s e d by
f o r c e i n its plane, is given by the f o r m u l a .
H = E't t Eft t E't (1:3)

1 1 2 2 c c
H = 2E't + E c' t c (for equal facings) (1:3a)
1 . 3 . 3 Sandwich S h e a r Stiffness
A sandwich that h a s f a i r l y thin facings on a t h i c k c o r e h a s a t r a n s v e r s e

s h e a r s t i f f n e s s p e r unit width given a p p r o x i m a t e l y by t h e f o r m u l a
. 2
U = -hG fi;'hG
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(1:4)
t C C
C
where t is t h e c o r e t h i c k n e s s and G is t h e c o r e s h e a r modulus a s s o c i a t e d

C C
with t h e d i s t o r t i o n of t h e T L o r T W plane ( s e e c h a p t e r 2 f o r d e t a i l s ) .
1-6

_- -
MIL-HDBK-23A CHG NOTICE 3 9999970 0347864 659
FACING ZL.
COR
t t t t
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
t t t t
A.- GNRA L BUCKLING B. - SHEAR CRIMPING
t t t t t t t t t t t t .
C, - DIMP ING .- WRINKLING OF FACINGS
OF FACING:
n 117 044
-
F i g u r e 1 1. - - P o s s i b l e modes of f a i l u r e of sandwich composite under
edgewise loads: G e n e r a l buckling, s h e a r c r i m p i n g , dimpling of fac -
i n g s , and wrinkling of facings e i t h e r away f r o m o r into the c o r e .

-. - ~
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 0147865 595
t I/
CORE
FAC/NG I-
F i g u r e 1-2. --Sketch showing notation for sandwich composite.
M 119 6 2 3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Provided by IHS
. Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard
__I_
-
MIL-YDBK-23A C Y G N O T I C E 3 M 9999970 0147bb 4 2 1 m
/. /6
/. / 4 ---I-- l t h ?'
D=K-
2 A
/. /z
/./O
K /.O8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
/. 06
/. 04
t o./o0
/*02 1 0.040 E'

o.o20
o.o/o
o.oo/
O
/.O 0
O o.O 4 O.08 o./2 O./6 o.20
?131
l 3ih
t/h
F i g u r e 1 - 3 . - - E f f e c t of facing s t i f f n e s s ( P a r a m e t e r t / h ) and c o r e s t i f f n e s s
( p a r a m e t e r E ' / E ' ) on the bending s t i f f n e s s of sandlvich.
C

mL-HDBK-23A CHG N O T I C E 3 9999970 0147867 3 6 8
MIL -HDBK- 2 3 A
3 0 Dec 1-968
CHAPTER 2
MATER IALS
2. 1 FACING MATERIALS
2. 1. 1 Functions, D e s c r i p t i o n s , U s u a l Fo.rms
T h e facings of a sandwich p a r t s e r v e many p u r p o s e s , depending upon the

application, but in a l l c a s e s they c a r r y the m a j o r applied loads. The stiff-
n e s s , stability, configuration, and, t o a l a r g e extent, the s t r e n g t h of the
p a r t a r e d e t e r m i n e d by the c h a r a c t e r i s t i c s of the facings a s stabilized h y
the c o r e . To p e r f o r m t h e s e functions the facings m u s t be adequately bonded
t o a c o r e of acceptable quality. Facings s o m e t i m e s have additional functions,
s u c h a s providing a profile of p r o p e r aerodynamic s m o o t h n e s s , a rough non-
s k i d s u r f a c e , o r a tough w e a r - r e s i s t a n t floor covering. T o b e t t e r fulfill
t h e s e s p e c i a l functions, one facing of a sandwich is s o m e t i m e s m a d e thicker
o r of slightly different construction than the o t h e r .
Any thin, s h e e t m a t e r i a l c a n s e r v e a s a sandwich facing. A few of the

m a t e r i a l s usually u s e d a r e d i s c u s s e d b r i e f l y in the following:
2 . 1. 1. 1 M e t a l s ( r e f . 2 - 3 5 )
2 . 1 . 1 . 1 . 1 Aluminum Alloys. - - T h e s t r o n g e r alloys of aluminum, such

a s 7075-T6, 2024-T3, o r 2014-T6, a r e commonly u s e d a s facings f o r s t r u c -
t u r a l a s w e l l as f o r n o n s t r u c t u r a l sandwich applications.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
2-1

NIL-HDBK-23A CHG N O T I C E 3 = 9999970 0147868 2 T 4 W
2. 1. 1 . 1 . 2 Steel Alloys. --Stainless s t e e l s h e e t s a r e finding i n c r e a s i n g

u s e as a facing m a t e r i a l i n airframe sandwich construction. T h e chief
advantage of s t a i n l e s s s t e e l s h e e t is its high s t r e n g t h a t elevated t e m p e r a -
t u r e s . Alloys s u c h as 18-8, 17-7PH, and PH15-7Mo a r e c u r r e n t l y finding
use because high s t r e s s e s c a n be r e a l i z e d . T h e 18-8 alloys can be r o l l e d
t o v a r i o u s d e g r e e s of h a r d n e s s t o produce high s t r e n g t h but it should be
understood that a s h e e t rolled full h a r d h a s a longitudinal c o m p r e s s i v e yield
s t r e s s about one-half of the c o m p r e s s i v e yield s t r e s s i n the t r a n s v e r s e
d i r e c t i o n . T h i s d i s c r e p a n c y c a n b e closed by subsequent s t r e s s relief.
Alloys of the 17-7PH and PH15-7Mo a r e precipitation hardenable and c a n be
s t r e n g t h e n e d by heat t r e a t m e n t - - u s u a l l y t o condition TH1050.
L. 1 . 1. 1 . 3 Titanium Alloys. --Alloys of titanium a r e c u r r e n t l y of i n t e r e s t

as facing m a t e r i a l s because of t h e i r high strength-weight r a t i o s and b e c a u s e
they can be u t i l i z e d f o r m o d e r a t e l y high tempe r a t u r e applications.
2. 1. 1. 1. 4 Magnesium Alloys. --Magnesium alloy s h e e t s have been used

only e x p e r i m e n t a l l y as facing m a t e r i a l s , but m a y find i n c r e a s i n g application
. b e c a u s e of t h e i r low d e n s i t y .
2. 1. 1 . 1 . 5 Nickel B a s e Alloys. --Nickel b a s e alloys s u c h as Ren 41 c a n

be utilized f o r h e a t - r e s i s t a n t sandwich at t e m p e r a t u r e s of 1 2 0 0 " -1500" F.
Ren 41 is a precipitation-hardening alloy that needs protection f r o m the
a t m o s p h e r e during heat t r e a t i n g . T h e alloy can be welded.
2. 1. 1. 1 . 6 Cobalt B a s e Alloys. --Alloys of cobalt with c h r o m i u m , n i c k e l ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
molybdenum, and tungsten a r e available f o r use in m o d e r a t e l y s t r e s s e d appli-
cations at t e m p e r a t u r e s of 1000" -1800" F. Alloys s u c h as L 6 0 5 c a n be
b r a z e d , o r fusion o r r e s i s t a n c e welded.
2. 1. 1. 1 . 7 Columbium Alloys. - -Columbium alloys D-36, D-43, and

Cb-752 a r e s u i t a b l e f o r use a t t e m p e r a t u r e s up t o 2500" F i f they a r e p r o -
tected f r o m oxidation by thin s i l i c i d e coatings. T h e s e alloys c a n be b r a z e d
i n a n i n e r t a t m o s p h e r e o r c a n be welded; however, degradation c a n be m i n -
i m i z e d by joining p a r t s by diffusion bonding.
2. 1. 1. 1. 8 Molybdenum Alloys. --Alloy T Z M of molybdenum can r e s i s t

t e m p e r a t u r e s up t o 2800" F. N e e d f o r protection and m e a n s of joining p a r t s
a r e the s a m e as f o r the columbium a l l o y s .
2. 1 . 1. 1. 9 Beryllium. - - T h e low weight and high e l a s t i c modulus of

b e r y l l i u m m a k e i t m o s t a t t r a c t i v e f o r use in sandwich c o m p o s i t e s . T h e
-
metal is heat r e s i s t a n t i n t h e r a n g e 1000"-1200" F. Parts c a n be joined by
b r a z i n g o r welding. P r e c a u t i o n s m u s t be t a k e n t o prevent individuals f r o m
inhaling toxic b e r y l l i u m p a r t i c l e s d u r i n g fabrication of p a r t s .

- - .
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0147869 130 m
e 2. 1. 1. 2 Reinforced P l a s t i c M a t e r i a l s ( r e f . 2-34)
2. 1. 1. 2. 1 Glass - F a b r i c Reinforced. - -Resin-impregnated g l a s s -fabric

facings p o s s e s s acceptable p r o p e r t i e s for s t r u c t u r - a l sandwiches when p r o p -
e r l y fabricated. Because of i t s excellent d i e l e c t r i c c h a r a c t e r i s t i c s when
f a b r i c a t e d with the p r o p e r r e s i n , this type of facing is used a l m o s t univer-
s a l l y f o r r a d o m e s of sandwich construction. A v a r i e t y of weaves a r e avail-
able c o m m e r c i a l l y , which makes it p r a c t i c a b l e , by orienting the fiber d i r e c -
tions i n the facing, to achieve a wide r a n g e of d i r e c t i o n a l s t r e n g t h p r o p e r t i e s .
In many a i r f r a m e applications, facings a r e exposed to m o i s t u r e , e i t h e r

in the f o r m of high humidity o r f r e e w a t e r . Even though the amounts of m o i s -
t u r e a b s o r b e d by g l a s s - r e i n f o r c e d plastic a r e quite s m a l l (on the o r d e r of
O . 5 to 1 . 5 p e r c e n t ) , the s t r e n g t h p r o p e r t i e s a r e d e c r e a s e d , with the amount
of d e c r e a s e depending upon the type of finish applied to the g l a s s f a b r i c .
C u r r e n t specification r e q u i r e m e n t s p e r m i t only s m a l l l o s s e s of s t r e n g t h ,
a f t e r e x p o s u r e to m o i s t u r e , that a r e consistent with r e s u l t s of t e s t s on f a b r i c s
m a d e with m o r e r e c e n t and effective finishes ( s u c h a s Volan A , A - 1 1 0 0 ,
C a r a n RS-49, T - 3 1 , NOL-24, and A-172). The m o s t suitable finish for a
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
given application i s s e l e c t e d by the g l a s s f a b r i c a t o r . F o r c h e m i c a l

r e s i n types, s u c h a s phenolic, epoxy, and t r i a l l y l c y a n u r a t e - p o l y e s t e r r e s i n s ,
optimum p r o p e r t i e s a r e obtained by use of specific finishes with each r e s i n
formulation. The acceptable finishes for e a c h approved r e s i n a r e given in
the qualified products lists that accompany the m i l i t a r y specification for each
c h e m i c a l type of r e s i n .
2. 1. 1. 2. 2 Glass Mats Reinforced. - - G l a s s f i b e r s a r e a l s o c o m m e r c i a l l y

available in the f o r m of m a t s , but owing to the r e l a t i v e nonuniformity in
thickness and r e s i n content and because of the low s t r e n g t h when c o m p a r e d
to g l a s s f a b r i c , m a t s have found l i t t l e use in a i r c r a f t sandwich construction.
2 . 2 SANDWICH CORES
2. 2 . 1 DescriDtion of C o r e s
T o p e r m i t an a i r f r a m e sandwich construction to p e r f o r m s a t i s f a c t o r i l y ,
the c o r e of the sandwich m u s t have c e r t a i n mechanical p r o p e r t i e s , t h e r m a l
c h a r a c t e r i s t i c s , and d i e l e c t r i c p r o p e r t i e s under conditions of use and s t i l l
conform t o weight limitations. C o r e s of d e n s i t i e s ranging f r o m 1. 6 to
23 pounds p e r cubic foot have found use i n a i r f r a m e sandwich, but the usual
density r a n g e is 3 to 10 pounds p e r cubic foot. Specifications for c o r e s
intended for use i n a i r f r a m e s a r e l i s t e d i n 2. 2. 1. 1.
Various c o r e p r o p e r t i e s a r e given i n U. S . C u s t o m a r y Units. Conversion

t o the International S y s t e m of Units can be m a d e by using f a c t o r s given i n
Notation at the front of the Handbook.
2- 3
x__ ----___

___-__ __ ___-
MIL-HDBK-23A CHG NOTICE 3 9999970 0347870 9 5 2
2. 2. 1. 1 C o r e Specifications
Suec i f i c at ion C o r e type Referenced

document No.
M I L -C - 7 4 3 8 Aluminum 2-38
M I L - C - 83 7 3 P l a s t i c Honeycomb, Laminated
G l a s s Fabric Base 2-39
M I L -C - 8 0 8 7 F o a m e d -111 - P l a c e ,
U rctliaiie Type 2-40
-
MIL -C 2 1275 Metallic, Heat - R e s i s t a n t 2-41
MIL - S - 79 9 8 Balsa Wood 2-43
MIL -S - 25 39 2 G l a s s F a b r i c Bas<,
Laininatctd Facings and
U rcthanrs Foamed-In- P l a c c
Core 2-44
M I L -L - 7 9 7 0 M a h o g any 2-42
2. 2. 1. 2 C o r e Index
T h e c o r e s for which s t r e n g t h d a t a have been g e n e r a t e d and included i!;

t h i s docuinent a r e l i s t e d below.
Cellular ( H o n i ~ y c o m b )
Hexagonal and s quar e c e l l s
Aluminuin - 3003-Hl9
505 2-H 39
5056-H39
20 2 4 4 4
20 2 4 - T 8 1
G l a s s fabric -
Phenolic r e s i n
Xylon-phenolic r e s i n
Phenolic -polyester r e s i n
Polyester resin
Silicone r e s i n
Polyimide r e s i n
Asbestos f a b r i c - Phenolic r e s i n
Silicone r e s i n
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

___--___- ___-
P l a s t i c film - Polyester
P o l yimi d e
Polyamid e
Paper - Phenolic r e s i n
Epoxy r e s i n
Steel - 17-7PH conditions A , T , and TH1050

PH15-7Mo condition A
AM3 50 condition A
321 conditions A and 1 / 2 h a r d
A286
H e a t - r e s i s t a n t alloy - Inconel
Cobalt L-605
T ZM Molybdenum
D3 6 Columbium
Titanium - Ti75A
Formable cells
Aluminum - 1145-H19
3 003 - H l 9
5052-H38
P a p e r -epoxy r e s in
Crossbanded - Aluminum 5052-H39
Corrugated
Glass fabric - Polyester resin
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Steel - 301 ( 1 / 2 hard)
AM355
Foams
F o a m e d plastic - Cellular cellulose a c e t a t e

P o l y e s t e r -Diisocyanate
Alkyd -Iso cyanat e
Silicone r e s i n
Epoxy-phenolic r e s i n
F o a m e d glass
F o a m e d aluminum
Natur al
B a l s a wood -
2 -5

I
MIL-HDBK-23A C H G NOTICE 3 '3999970 0 1 4 7 8 7 2 725
2 . 2 . 1 . 2 . 1 C e l l u l a r (Honeycomb) C o r e . - - A wide v a r i e t y of c o r e m a t e r i a l s
c a n be c o n s t r u c t e d of thin s h e e t m a t e r i a l s o r ribbons f o r m e d to honeycomb-
like configurations. By varying the s h e e t m a t e r i a l , s h e e t t h i c k n e s s , c e l l ,
s i z e , and c e l l s h a p e , c o r e s of a wide range in density and p r o p e r t i e s c a n be
produced. Various c o r e configurations a r e shown i n f i g u r e s 2 - 1 through 2-4.
Most honeycomb c o r e s p r e s e n t l y available a r e of c e l l s of types A , E , o r F
shown in figure 2-1. Most honeycomb c o r e s can be f o r m e d t o m o d e r a t e
amounts of s i n g l e c u r v a t u r e , but c o r e s s h o v n i n f i g u r e 2 - 2 of types A , B y C , D,
and G cells can be e a s i l y f o r m e d t o f a i r l y s e v e r e single c u r v a t u r e and t o
m o d e r a t e compound c u r v a t u r e ( s p h e r i c a l s h a p e s ) . Type A c o r e ( f i g . 2 - 2 ) m a y
have the s t r a i g h t ribbon of p r i m a r y c o r r u g a t e d foil the full c o r e t h i c k n e s s , in
which c a s e f o r m i n g t o single c u r v a t u r e is e a s y , o r the s t r a i g h t ribbon m a y I
be only a portion of the c o r e t h i c k n e s s , s o t h a t forming to compound c u r v a t u r e

i s e a s i l y done.
C o r e s of type F (fig. 2 - 2 ) c e l l s f o r m readily to c y l i n d r i c a l shape and to a

r a d i u s approaching half the c o r e t h i c k n e s s ; c o r e s of type E c e l l s f o r m readily
t o s p h e r i c a l shape and of a radius approaching twice the c o r e t h i c k n e s s ; and
c o r e s of types D and G c e l l s t o v a r i o u s single o r compound c u r v a t u r e s h a p e s .
Honeycomb c o r e c e l l s i z e is d e t e r m i n e d by the d i a m e t e r of a c i r c l e which

c a n be i n s c r i b e d i n a cell. Sketches of two types of honeycomb c o r e showing
the cell s i z e " s " are shown i n figure 2-5. Honeycomb c o r e c e l l s i z e s used
i n a i r c r a f t v a r y f r o m about 1 / 1 6 t o 7 / 1 6 inch, usually in multiples of 1 / 1 6 inch.
Not all s h e e t m a t e r i a l s a r e f o r m e d to a l l of t h e s e c e l l s i z e s because s o m e
s h e e t m a t e r i a l s a r e s o thick and stiff that they cannot be f o r m e d to c o r e of
c e l l s less than 3 / 1 6 inch i n s i z e . F o r s p e c i a l u s e , s u c h as an i n s e r t , honey-
c o m b cores c a n be densified locally by under-expanding o r by c r u s h i n g the
cells together. Such densified c o r e h a s p r o p e r t i e s i n c r e a s e d approximately
i n proportion t o density i n c r e a s e . C o r e s f o r airframe sandwich construction
a r e presently being m a d e of thin s h e e t s of aluminum a l l o y s , r e s i n - t r e a t e d
glass fabric, resin-treated asbestos, resin-treated paper, stainless steel
alloys, t i t a n i u m a l l o y s , and r e f r a c t o r y m e t a l s .
Honeycomb c o r e s fabric.ated f r o m nonmetallic m a t e r i a l s have b e t t e r

t h e r m a l insulating c h a r a c t e r i s t i c s than m e t a l l i c honeycomb c o r e s , even
though both allow t r a n s m i s s i o n of heat by radiation in the open c e l l s . In
considering t h e r m a l effects on sandwich s t r u c t u r e , i t should be understood
that t h e sandwich c a n a c t as a r e f l e c t i v e t h e r m a l i n s u l a t o r .
T h e effective t h e r m a l conductivity of a honeycomb c o r e depends upon

conduction of t h e m a t e r i a l of which the c o r e is m a d e , radiation between f a c - ._
i n g s , and convection within the c o r e cell (ref. 2 - 2 2 , 2-30) and c a n be c o m -
puted approximately with t h e f o r m u l a
2- 6 .~
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 03q7873 bbL
,
t
3
4ut (1
C
-
K = K A f 1 Ac)Tm -f- tc( 1-Ac)q
e o c 2
-
E
t-
E
- 2 t
1 2 F12 +
where K
e
-- effective conductivity
K
O
-- conductivity of c o r e ribbon m a t e r i a l
A
C
-- c o r e solidity, A
C =w c p o
w
C
-- c o r e density
w
O
-- c o r e ribbon m a t e r i a l density
u -- Stefan-Boltzmann constant .
t -- c o r e thickness
C
T - - m e a n absolute t e m p e r a t u r e of the two sandwich facings
m
E
1
-- e m i s s i v i t y of inside of sandwich facing 1
E - - e m i s s i v i t y of i n s i d e of sandwich facing 2
2
F12
-- g e o m e t r i c view f a c t o r between facings ( r e f . 2-17)
q -- convective heat t r a n s f e r coefficient inside c o r e c e l l
Sheets of c o r r u g a t e d m e t a l foil a r e usually a s s e m b l e d with the c o r r u g a -

tions p a r a l l e l to f o r m honeycomb c o r e s . The foil m a y be p e r f o r a t e d for u s e
in c o r e w h e r e solvents o r g a s e s m u s t be vented. P e r f o r a t e d foil in sandwich
panels that a r e not s e a l e d o r a r e poorly s e a l e d will allow penetration of
m o i s t u r e e t c . , which m a y c a u s e s e v e r e d e t e r i o r a t i o n of the c o r e . If the
s h e e t s a r e a s s e m b l e d with the c o r r u g a t i o n s i n adjacent s h e e t s perpendicular
to e a c h o t h e r , a well-vented c r o s s b a n d e d c o r e i s produced. Crossbanded
c o r e s m a y b e cut s o that the c o r r u g a t i o n flutes a r c a t an angle of 4 5 " to the
sandwich facings, giving the c o r e a t r u s s e d a p p e a r a n c e . A sandwich panel
with t h i s type of c r o s s b a n d e d c o r e is shown in figure 2 - 3 .
C r o s s b a n d e d c o r e s a r e not as s t r o n g i n c o m p r e s s i o n in the T d i r e c t i o n
o r i n s h e a r i n the T L o r TW planes ( s e e fig. 2-5) a s honeycomb c o r e s of the
s a m e density. Honeycomb c o r e s , however, have negligible c o m p r e s s i v e
s t r e n g t h i n the W and L d i r e c t i o n s and s h e a r s t r e n g t h in the WL plane,
w h e r e a s c r o s s b a n d e d c o r e s have considerable s t r e n g t h in t h e s e d i r e c t i o n s .
Because of the many c r o s s connections between c o r e f l u t e s , c r o s s b a n d e d

c o r e is p a r t i c u l a r l y adapted t o construction of a i r f r a m e sandwich panels with
i n t e g r a l fuel tanks.
2-7
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-_ _
-
MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 7 8 7 4 5 T
C r o s s b a n d e d c o r e is not r e a d i l y f o r m e d to c u r v e d s u r f a c e s because of
its r e l a t i v e l y high s t i f f n e s s in all d i r e c t i o n s . Curved p a r t s and p a r t s of
unusual s h a p e could, however, be m a c h i n e d f r o m blocks of c r o s s b a n d e d c o r e ,
2. 2. 1.2. 2 C o r r u g a t e d C o r e . - - C o r r u g a t e d c o r e s a r e produced by f o r m -
ing a s h e e t of m e t a l foil o r r e s i n - t r e a t e d g l a s s cloth t o a s e r i e s of s i n e wave
c o r r u g a t i o n s . F i g u r e 2 - 4 shows sketches of sandwich having single and double
r o w s of c o r r u g a t i o n s . T h e c o r r u g a t i o n flutes r u n p a r a l l e l to the f a c i n g s ,
w h e r e a s honeycomb c o r e c e l l a x e s a r e n o r m a l t o the f a c i n g s . C o r r u g a t e d
c o r e s m a y b e f o r m e d to s i n g l e c u r v a t u r e . Approximate t h e r m a l conductivity
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
e x p r e s s i o n s f o r c o r r u g a t e d c o r e a r e given in r e f e r e n c e 2 - 3 0 .
2. 2. 1 . 2. 3 Waffle-Type C o r e . - - C o r e s of s h e e t m a t e r i a l f a b r i c a t e d into
a configuration r e s e m b l i n g a waffle have been produced. Sheets of r e s i n -
t r e a t e d g l a s s - f i b e r m a t have been f o r m e d t o waffle-type c o r e for u s e i n
r a d o m e s . Thin metal s h e e t s e m b o s s e d o r dimpled into a waffle configuration
of r o w s of s q u a r e o r t r i a n g u l a r lands on e i t h e r s i d e have been manufactured.
T h e waffle-type c o r e d o e s not lend i t s e l f well t o sandwich constructions that
require tapered core thickness.
2. 2. 1 . 2 . 4 F o a m C o r e s . - - T o o v e r c o m e t h e principal disadvantages of
n a t u r a l c o r e m a t e r i a l s , p a r t i c u l a r l y undesirable v a r i a t i o n in density and
m o i s t u r e absorption, a t t e m p t s have been m a d e t o develop synthetic c o r e
m a t e r i a l s having s a t i s f a c t o r y p r o p e r t i e s . P l a s t i c c o r e s a r e f o a m e d , expanded,
o r p r o c e s s e d by o t h e r m e a n s t o r e d u c e the apparent density of the p l a s t i c t o
a p r a c t i c a l r a n g e f o r c o r e m a t e r i a l . The expanding p r o c e s s e s a r e subject to
c o n t r o l ; consequently, t h e p r o p e r t i e s of t h e r e s u l t i n g c o r e m a t e r i a l can be
predicted. Metallic foamed c o r e s c a n be produced by mixing molten
a l u m i n u m - m a g n e s i u m alloys with s u i t a b l e foaming agents and cooling the
m i x t u r e t o f o r m a porous s o l i d . G l a s s f o a m s can a l s o be produced.
2.2.1.2.4. 1 Foamed-in-place c o r e m a t e r i a l s . - - I n o r d e r to obtain

n e c e s s a r y r a d i a t i o n - t r a n s m i s s i o n c h a r a c t e r i s t i c s , c e r t a i n types of r a d o m e s
r e q u i r e sandwich construction with homogeneous facings and c o r e , together
with t a p e r i n g thickness of t h e sandwich and c l o s e control of thickness through-
out ( r e f s . 2 - 2 , 2 -23, 2 - 3 1). T o obtain all t h e s e c h a r a c t e r i s t i c s , foamed-in-
place c o r e m a t e r i a l s have been developed that \rill a d h e r e to a c c u r a t e l y p r e -
m o l d e d g l a s s - f a b r i c - b a s e p l a s t i c f a c i n g s . T h i s type of c o r e m a t e r i a l , v:hile
not as s t r o n g o r stiff as g l a s s - f a b r i c honeycomb c o r e of the s a m e d e n s i t y ,
o f f e r s t h e s e advantages: C o r e joint elimination; thin and uniform bonding
l a y e r between facings and c o r e ; u s e of a c c u r a t e l y p r e m o l d e d , void-free
facings t h a t can be r e a d i l y inspected before a s s e m b l y ; good e l e c t r i c a l p r o p -
e r t i e s ; and flexibility i n m a n u f a c t u r e .
2-8

e .
S a t i s f a c t o r y c o r e m a t e r i a l has been m a d e f r o m formulations based on
combinations of alkyd r e s i n s and metatolylene diisocyanate. It h a s been
p o s s i b l e to produce f o a m s of uniform density of 3 to 30 pounds per cubic foot,
but m a t e r i a l s of a density of 10 t o 16 pounds p e r cubic foot a r e m o s t commonly
) used ( r e f . 2-16, 2-27). In addition to t h e i r use in r a d o m e s , alkyd-
diisocyanate f o a m s have a l s o been used to a l i m i t e d extent t o s t a b i l i z e the
s k i n s of hollow s t e e l p r o p e l l e r blades and aluminum alloy c o n t r o l s u r f a c e s ,
p a r t i c u l a r l y for complex configurations i n which honeycomb c o r e m a t e r i a l s
cannot r e a d i l y be used. Other foamed-in-place c o r e m a t e r i a l s which have
been produced e x p e r i m e n t a l l y are foamed polyester and silicone r e s i n s
( r e f . 2-28, 2-31).
The t h e r m a l insulation of f o a m e d - i n - p l a c e c o r e is good as c o m p a r e d to

honeycomb c o r e . F i g u r e 2 - 6 p r e s e n t s the r e s u l t s of l i m i t e d t e s t s on s a n d -
. wich panels having alkyd-isocyanate and phenolic honeycomb c o r e s ( r e f . 2-24).
2. 2. 1. 2.4. 2 Other f o a m e d p l a s t i c s . --Cellular cellulose a c e t a t e h a s

been extruded to f o r m s t r i p s of c o r e similar to alkyd-isocyanate, but l a c k -
ing the advantqges of foaming i n place ( r e f . 2-20). S e v e r a l types of foamed
p l a s t i c s have been produced on a laboratory' b a s i s , such as foamed polysty-
r e n e , foamed synthetic r e s i n s , and c e l l u l a r t h e r m o p l a s t i c s , but none have
shown sufficient p r o m i s e t o be offered on a c o m m e r c i a l s c a l e f o r a i r c r a f t
f a b r i c a t i o n ( r e f . 2-3, 2 - 2 6 , 2-31).
2. 2. 1. 2.4. 3 Epoxy-phenolic, aluminum-filled foam. - - T h i s is a r e l a -

tively heavy foam c o r e with a density of 18 t.o 30 pounds p e r cubic foot. It is
used i n l o c a l a r e a s i n m e t a l honeycomb c o r e w h e r e i n c r e a s e d s t r e n g t h is
needed ( r e f . 2-15).
2. 2. 1. 2.4. 4 Metallic f o a m . - - F o a m e d a l u m i n u m - m a g n e s i u m alloy c o r e s

have been produced e x p e r i m e n t a l l y i n d e n s i t i e s of about 15 t o 35 pounds p e r
cubic foot ( r e f . 2-1).
2. 2. 1 . 2 . 4 . 5 G l a s s foam. - - G l a s s f o a m h a s been produced e x p e r i m e n t a l l y

i n a density of about 9 pounds p e r cubic foot.
2. 2. 1. 2. 5 N a t u r a l C o r e s . - - T h e s e l e c t i o n of n a t u r a l c o r e m a t e r i a l s f o r
a i r f r a m e sandwich is confined principally to b a l s a wood, with mahogany,
s p r u c e , and poplar being used f o r i n s e r t s and edgings.
T h e t h e r m a l conductivity of wood a c r o s s the g r a i n c a n be computed by

the f o r m u l a ( r e f . 2-46).
k = (1. 39 t O. 028M)S t O. 165
2-9
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~ . _ _ _ ~ _ _ ~ -
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 7 7 0 0347876 370
2
where k -- conductivity ( B t u in. / h r f t F")
M -- m o i s t u r e content, ( p e r c e n t )
S -- specific gravity of wood
The t h e r m a l conductivity p a r a l l e l to the g r a i n is about 2 - 1/ 2 t i m e s that

a c r o s s the g r a i n (ref. 2-46).
2. 2. 1. 2. 5. 1 B a l s a . - - B a l s a wood can be used with the g r a i n d i r e c t i o n

o r i e n t e d p a r a l l e l o r perpendicular to the sandwich facings. The p r e s e n t
p r a c t i c e is to place the g r a i n perpendicular to the facings --"end-grain"
application ( r e f . 2-5, 2-10, 2-20, 2 - 2 6 , 2-50).
2. 2. 1. 2 . 5 . 2 Mahogany, s p r u c e , and poplar. - - C e r t a i n portions of s a n d -

wich p a n e l s , s u c h a s points of attachment and exposed e d g e s , r e q u i r e a high-
s t r e n g t h i n s e r t ( r e f . 2-4, 2-32, 2 - 3 3 ) . End-grain mahogany i s s o m e t i m e s
used a t t h e s e points. The density of t h i s mahogany, d e t e r m i n e d by weight
and m e a s u r e m e n t of planed b o a r d s at a m o i s t u r e content of 8 to 12 p e r c e n t ,
is n o r m a l l y between 25 and 35 pounds p e r cubic foot.
A s a substitute f o r mahogany, e n d - g r a i n s p r u c e h a s s o m e t i m e s been

used f o r i n s e r t s . Its r e l a t i v e l y poor machinability a c r o s s the g r a i n and dif-
ficulty in bonding to the end-grain s u r f a c e have limited i t s use to an o c c a -
s i o n a l e x p e r i m e n t a l o r e m e r g e n c y application. End-grain poplar is r e p o r t e d
to have found limited use for c o r e i n s e r t s . I t s selection for density and
quality should be s i r n i l a r to that for mahogany. Edgings of sandwich panels
s o m e t i m e s include a band of plywood because of partially e n d - g r a i n m a t e r i a l
and because the dimensional stability of s u c h edge m a t e r i a l i s f a i r l y good.
2.2.2 Mechanical P r o p e r t i e s of C o r e s
2. 2. 2. 1 Strength P r o p e r t i e s at N o r m a l T e m p e r a t u r e s
T h e m e c h a n i c a l p r o p e r t i e s of c o r e m a t e r i a l s a s s o c i a t e d with t h e i r n a t u r a l
a x e s at n o r m a l t e m p e r a t u r e s ( 7 0 " - 7 5 " F ) as d e t e r m i n e d f r o m t e s t s of
small s p e c i m e n s a r e given in t a b l e s 2-1 and 2 - 2 . Axes notation for c o r e
p r o p e r t i e s i n the different d i r e c t i o n s specified i n the tables a r e i l l u s t r a t e d
in f i g u r e s 2 - 5 and 2-7 and explained i n d e t a i l in footnote 1 of the two t a b l e s .
F o r e a c h m a t e r i a l , the a v e r a g e density and mechanical p r o p e r t i e s a r e given.
T h e s t a n d a r d deviation and number of s p e c i m e n s evaluated a r e included to
indicate the variability and reliability of the d a t a as an aid in selection of
d e s i g n values. Average values and n u m b e r s f s p e c i m e n s of h e a t - r e s i s t a n t
c o r e s t e s t e d at n o r m a l t e m p e r a t u r e s a r e given, along with d a t a a t elevated
t e m p e r a t u r e s , i n t a b l e s 2 - 3 , 2-4, 2-5.
2-10
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

c
C o r e materials a r e s o m e t i m e s difficult to t e s t because they m a y not have
sufficient rigidity o r h a r d n e s s to support s t r a i n gages o r because they m a y
be available only i n thin s h e e t s . A number of methods of t e s t have been
devised. They a r e d e s c r i b e d - i n d e t a i l i n M i l i t a r y Standard MIL-STD-43 1
( r e f . 2-45).
In s o m e of the t e s t s the bond between the c o r e m a t e r i a l and the t e s t appa-

r a t u s , o r between the c o r e m a t e r i a l and the facings when the m a t e r i a l is
t e s t e d as a sandwich, failed r a t h e r than t h e c o r e m a t e r i a l itself. T h i s h a s
been noted i n the t a b l e s . Such f a i l u r e s w i l l t a k e place in sandwich c o n s t r u c -
tion i n c o r p o r a t e d i n s t r u c t u r e s but not n e c e s s a r i l y at the tabulated s t r e n g t h
values because of the dependence of t h e s e values on the method of f a b r i c a - .
tion of the sandwich construction.
Mechanical p r o p e r t i e s of c o r e s a r e usually evaluated on small s p e c i m e n s
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
about 1 / 2 inch thick. While e l a s t i c moduli of c o r e s a r e unaffected by c o r e
t h i c k n e s s , t h e c o m p r e s s i v e and s h e a r s t r e n g t h s of honeycomb c o r e s m a y
v a r y with c o r e thickness b e c a u s e c o r e s t r e n g t h m a y depend upon the buckling
s t r e n g t h of the c e l l w a l l s , which is a function of the rati.0 of c e l l - w a l l width
t o c o r e thickness. F i g u r e 2-8 shows the effect of c o r e thickness on c o m p r e s -
s i v e s t r e n g t h f o r aluminum and paper honeycomb c o r e s ( r e f . 2-11, 2-12,
2-19). F i g u r e 2-9 shows t h e effect of c o r e thickness on the s h e a r s t r e n g t h
of aluminum and paper honeycomb c o r e s ( r e f . 2-8, 2-11, 2-13).
Mechanical p r o p e r t i e s of r e s i n - t r e a t e d paper honeycomb c o r e s depend

not only on the c o r e t h i c k n e s s , but a l s o on c o r e m o i s t u r e content. The
r e l a t i o n s h i p between r e l a t i v e humidity and c o r e m o i s t u r e content for two
k r a f t paper c o r e s is shown in figure 2-10. T h e effect of c o r e thickness and
m o i s t u r e content on s h e a r o r c o m p r e s s i v e s t r e n g t h is given i n the " c a r p e t
plot'' of f i g u r e 2-11. The r e l a t i v e s h e a r o r c o m p r e s s i v e s t r e n g t h is plotted
t o p e r m i t l i n e a r horizont a l interpolation f o r both the independent v a r i a b l e s
of m o i s t u r e content and c o r e thickness. F o r example, t h e r e l a t i v e r t r e n g t h
of a c o r e 3/4 i n c h thick and at 16 p e r c e n t m o i s t u r e content is found to be
53 p e r c e p t . The interpolation is shown by the d a s h e d l i n e s i n f i g u r e 2-11.
T h e effect of c o r e m o i s t u r e content on c o r e e l a s t i c p r o p e r t i e s is shown i n
f i g u r e 2-12.
Minimum values of c o r e c o m p r e s s i v e and s h e a r s t r e n g t h s and proportional

limit s t r e s s e s at n o r m a l t e m p e r a t u r e s ( 7 0 " - 75" F ) a r e presented in
t a b l e 2-6. T h e s e m i n i m u m v a l u e s a r e the lowest values obtained for the
m a t e r i a l s d e s c r i b e d i n t a b l e s 2 - 1 t o 2-5 f o r which at least 1 2 s p e c i m e n s w e r e
t e s t e d . The s t a t i s t i c a l a s s u r a n c e a s s o c i a t e d with t h e s e m i n i m u m values is
t h a t at least 78 p e r c e n t of t h e population w i l l exceed t h e s e values with a prob-
ability of 0.95, r e g a r d l e s s of t h e shape of the frequency distribution c u r v e of
t h e population ( r e f . 2-51). In g e n e r a l , the probability is O. 95 t h a t at least
100 (O. 0 5 ) l I n p e r c e n t of the population w i l l e x c e e d the lowest among the n
s t r e n g t h s obtained. A g r a p h of t h e s e p e r c e n t a g e values as a function of
s a m p l e s i z e , n , is given i n f i g u r e 2-13.
2-11
____--------- -

-___
flIL-HDBK-23A C H G N O T I C E 3 W 9999970 0347878 343
Minimum s t r e n g t h values given in table 2-6 a r e c o m p a r e d with values of

a v e r a g e s t r e n g t h l e s s two s t a n d a r d deviations i n the graphs of figures 2-14,
2-15, and 2-16. T h e s e graphs show that the d a t a for the v a r i o u s c o r e s have
l e a s t values of 12 t e s t s that a r e s e l d o m below a v e r a g e values l e s s two s t a n d -
a r d deviations.
2. 2.2. 2 Strength P r o p e r t i e s at Elevated T e m p e r a t u r e s
The mechanical p r o p e r t i e s of c o r e s a t elevated t e m p e r a t u r e s a r e p r e -

sented i n t a b l e s 2-3, 2-4, and 2-5. Most of the h e a t - r e s i s t a n t c o r e s i n
t a b l e 2-3 have t h e i r n o r m a l t e m p e r a t u r e p r o p e r t i e s p r e s e n t e d i n d e t a i l in
t a b l e s 2 - 1 and 2-2. Tables 2-4 and 2-5 p r e s e n t mechanical p r o p e r t i e s of
heat - r e s i s t a n t and r e f r a c t o r y m e t a l c o r e s . Average c o r e p r o p e r t i e s and
the number of s p e c i m e n s evaluated at each t e s t t e m p e r a t u r e a r e p r e s e n t e d
i n t a b l e s 2-3, 2-4, and 2-5 f o r each c o r e m a t e r i a l . Table 2-5 p r e s e n t s
values of the s h e a r modulus a t 7 5 " F. F i g u r e 2-17 shows the effect of e l e -
vated t e m p e r a t u r e s on the s h e a r modulus of h e a t - r e s i s t a n t c o r e s .
2.2. 2. 3 Fatigue P r o p e r t i e s of C o r e M a t e r i a l s
T h e m a j o r s t r e s s r e s i s t e d by a c o r e m a t e r i a l i n a sandwich construction
is s h e a r . Sandwich a i r f r a m e components subjected to many cycles of flex-
u r a l loading m u s t have c o r e s p o s s e s s i n g adequate s h e a r fatigue s t r e n g t h .
F i g u r e 2-18 p r e s e n t s s h e a r fatigue c u r v e s for four types of low-density c o r e 1
m a t e r i a l ( r e f . 2-49). F i g u r e 2-19 p r e s e n t s s h e a r fatigue c u r v e s for two
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
t y p e s of m e t a l honeycomb c o r e ( r e f . 2-14). Fatigue f a i l u r e s of alkyd-

isocyanate foamed-in-place c o r e s m a y occur e i t h e r n e a r the c o r e - f a c i n g
i n t e r f a c e o r through the c e n t e r of the c o r e p a r a l l e l to the facings. End-grain
b a l s a fails by s h e a r p a r a l l e l to the grain. G l a s s - f a b r i c honeycomb c o r e m a y
fail in fatigue by spalling of r e s i n f r o m the f a b r i c along l i n e s p a r a l l e l o r
perpendicular t o t h e c o r e f l u t e s , leaving the f a b r i c unsupported. Metal honey-
c o m b c o r e s fail in s h e a r fatigue by s h e a r buckling and diagonal tension c r a c k -
ing of the c e l l w a l l s . B r i t t l e foils tend to fail by c r a c k i n g and do not p e r f o r m
as w e l l i n fatigue as m o r e ductile foils which fail by s h e a r buckling. P e r -
forations tend to p r o m o t e fatigue c r a c k s and p r e m a t u r e f a i l u r e .
2 . 2 . 2.4 C r e e p P r o p e r t i e s of C o r e M a t e r i a l s
When a constant s h e a r s t r e s s i s applied to c o r e m a t e r i a l s , a c e r t a i n

amount of c r e e p m a y t a k e place. If the s t r e s s i s applied for long p e r i o d s ,
t h e c o r e m a y f a i l at a s t r e s s well below the s h o r t - t i m e s h e a r s t r e n g t h o r
undesirable deformations m a y occur Some c r e e p m e a s u r e m e n t s have been
e
m a d e on sandwich c o r e s ( r e f . 2-48), but c r e e p d a t a for the c o r e m a t e r i a l s

c u r r e n t l y being used in a i r f r a m e sandwich a r e not available. -.
2-12

__ -- ___-__
mIL-HDBK-23A CHG N O T I C E 3 9999970 0347879 O 8 T
2. 2. 2. 5 E s t i m a t i o n of C o r e P r o p e r t i e s
If c o r e p r o p e r t i e s have not been established by t e s t , i t i s possible to

obtain r e a s o n a b l e e s t i m a t e s by consideration of c o r e m a t e r i a l , density, and
configuration. C o n v e r s e l y , i f a design r e q u i r e s a c o r e with c e r t a i n p r o p e r -
t i e s , i t is possible to e s t i m a t e t h e density, m a t e r i a l , and configuration of
c o r e needed to obtain a s a t i s f a c t o r y sandwich construction.
The e l a s t i c moduli and s t r e n g t h of c o r e s of a p a r t i c u l a r m a t e r i a l i n c r e a s e

as c o r e density i n c r e a s e s . Thus i f p r o p e r t i e s a t a c e r t a i n density a r e known,
a l i n e a r extrapolation c a n be used t o obtain e s t i m a t e s of p r o p e r t i e s at a dif-
f e r e n t density. If p r o p e r t i e s of c o r e s of s e v e r a l d e n s i t i e s a r e known, a
c u r v i l i n e a r r e l a t i o n s h i p m a y be exhibited between p r o p e r t y and d e n s i t y , and
this should be used r a t h e r than a l i n e a r extrapolation.
F o r cellular (honeycomb) c o r e s , the density and e l a s t i c moduli c a n be

e s t i m a t e d f r o m p r o p e r t i e s of the foil o r ribbon m a t e r i a l , thickness of the
ribbons, and c o r e c e l l s i z e and shape.
E s t i m a t e s of honeycomb c o r e density can be made by determining the

amount of foil o r ribbon m a t e r i a l p e r unit volume of c o r e . Results f o r two
commonly used types of c o r e (Fig. 2 - 1 , A and F) a r e given by the f o r m u l a s :
8t
O
w =- w for c o r e with hexagon c e l l s
c 3s o
2t
O
w =- w for c o r e with s q u a r e c e l l s
C S O
where w is c o r e density; w i s density of foil o r ribbon m a t e r i a l ; t is

2 O O
thickness of foil o r ribbon m a t e r i a l ; and s i s c e l l s i z e ( d i a m e t e r of i n s c r i b e d

circle) a
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
The c o r e modulus of e l a s t i c i t y , E T , can be e s t i m a t e d by multiplying the
modulus of e l a s t i c i t y of the foil o r ribbon m a t e r i a l , E , by the r a t i o of c o r e
O
density to foil o r ribbon density:
W
- C
ET - wE O
O
2-13
-- -__
--
I
- - Provided by IHS
_- ~ ~ ~ - _ _ _ _
MIL-HDBK-23A C H G N O T I C E 3 I9999970 O147880 T 1
The c o r e s h e a r moduli can be e s t i m a t e d by considering only portions of

foil ribbons i n planes being d i s t o r t e d by s h e a r i n g f o r c e a s being effective and
then modifying by e x p e r i m e n t a l constants to d e t e r m i n e effective s h e a r m o d -
uli in other planes. Results f o r two commonly used types of c o r e a r e given
by the f o r m u l a s :
{ for c o r e with hexagon c e l l s
TW
=-
16t
30s
O C
o
i)
t
- O
for c o r e with s q u a r e c e l l s
TL - GTW = o
where G is foil o r ribbon s h e a r modulus.

O
T h e flatwise t e n s i l e s t r e n g t h of sandwich with honeycomb c o r e is d e t e r -

mined by s t r e n g t h of the bond between facing and c o r e , provided that the c o r e
foil o r ribbon m a t e r i a l is not failed in tension. The c o r e s t r e n g t h at foil
f a i l u r e ( F ) can be e s t i m a t e d by multiplying the foil o r ribbon s t r e n g t h by
ct
the r a t i o of c o r e density to foil o r ribbon density:
W
C
F =- F
ct w O
O
If t h e bond s t r e n g t h p e r unit length of bond fillet, , is known ( d e t e r m i n e d

FoB
by t e s t s of c o r e s ) , the sandwich t e n s i l e s t r e n g t h (bond f a i l u r e ) can be e s t i -
m a t e d by multiplying the bond s t r e n g t h p e r unit length of fillet by the length
of fillet p e r unit c o r e a r e a . This length of bond fillet p e r unit c o r e a r e a has
been found to be 4 / s for honeycomb c o r e s of hexagon o r s q u a r e cells. Thus
the sandwich t e n s i l e s t r e n g t h (bond f a i l u r e ) , FcB, can be e s t i m a t e d by:
4
= - FOB f o r c o r e with hexagon o r s q u a r e c e l l s
FcB s
T h e final sandwich flatwise t e n s i l e s t r e n g t h w i l l be given by the s m a l l e r of

the values of F o r F
ct cB
2- 14
i-
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

I_-
NIL-HDBK-23A CHG N O T I C E 3 = 9999970 -------

0147881 738 =
2. 2. 2 . 5 . 1 C o r r u g a t e d Core--Single Row of Corrugations ( r e f . 2-21). - -

E s t i m a t e s of density of c o r r u g a t e d c o r e having a single row of corrugations
c a n be m a d e using the f o r m u l a
h
C
l t - B ~~
w = w P
C O h
C
1 t -
t
O
where w
C
and w
O
a r e as defined previously and h
C
, p, and t
O
a r e defined and
B is given i n f i g u r e 2 - 2 0 for c o r e s with v a r i o u s corrugation s l o p e s , 8 , and
c o r r u g a t i o n r a d i i of R = O and R = O. 18 h e
O O C .
The c o r e a r e a A p e r unit width i n a plane perpendicular to the d i r e c t i o n

C
of the c o r r u g a t i o n flutes is given by
h
C
A = t (1 t - B )
C O P
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
w h e r e B is given i n f i g u r e 2-20. The c o r e modulus of e l a s t i c i t y E in a

C
d i r e c t i o n p a r a l l e l to the c o r e flutes is given by
h
C
1 t - B
E = E P
C O h
C
1 t -
t
O
where E is the modulus of e l a s t i c i t y of the c o r e foil m a t e r i a l . The c o r e

O
m o m e n t of i n e r t i a I p e r unit width is given by
C
3
h t
1 =-- o ( It 4c)
c 4 P h c
where h , t , and p a r e defined and C is given i n f i g u r e 2 - 20 f o r c o r e s with

C O
v a r i o u s c o r r u g a t i o n s l o p e s , 8, and c o r r u g a t i o n r a d i i of R = O and
O
R
O
= 0.18 h
C
.
2-15

MIL-HDBK-23A CHG N O T I C E 3 9999970 0147882 674 =
T h e c o r e s h e a r modulus a s s o c i a t e d with a s h e a r f o r c e perpendicular t o
t h e d i r e c t i o n of t h e c o r r u g a t i o n f l u t e s m a y be e s t i m a t e d by t h e f o r m u l a
2
where X
O
= 1 - po, pO is t h e P o i s s o n ' s r a t i o of the c o r e foil m a t e r i a l , and
S is given i n t h e g r a p h s of f i g u r e 2-21 f o r R = O. 18 h and i n f i g u r e 2 - 2 2 f o r
O C
R = O. A s R / h i n c r e a s e s , the value of S i n c r e a s e s slightly. The p a r a m -
O o c
eter S is r e l a t i v e l y insensitive t o v a r i a t i o n s i n the r a t i o h / t when h / t
C O C O
is 30 o r l a r g e r . The g r a p h s w e r e d r a w n f o r h /t = 40. T h e c h a r t s for S
C O
are f o r sandwich with similar facings ( E = E and t = t 2 ) . If the facings
1 2 1
a r e d i s s i m i l a r a good approximation (within 3 p e r c e n t ) m a y be obtained f r o m
the f o r m u l a
1.26 S , S ,
1 L i
S =
( S i t Sl) ll3
where S and S a r e t h e values of S d e t e r m i n e d f r o m the graphs of f i g u r e s 2 - 21

1 2
o r 2- 22, a s s u m i n g t h a t both facings a r e similar to facings 1 and 2 , r e s p e c t i v e l y .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
2. 2. 2.5. 2 C o r r u g a t e d Core--Double Row of Corrugations ( r e f . 2-21,
2-25. - - F o r e s t i m a t i n g t h e p r o p e r t i e s of a c o r e having two r o w s of c o r r u -
-
gations (fig. 2-4), t h e d i m e n s i o n s p and h apply t o one of t h e r o w s of c o r -
L
rugations and a r e again defined i n f i g u r e 2 - 20. T h e c o r e density s again

given by
h
C
I t - B
w = w P
C O h
C
1 t -
t
O
The c o r e area A p e r unit width, i n a plane perpendicular t o the d i r e c -

c2
tion of t h e c o r r u g a t i o n f l u t e s is given by
h
A = 2t ( 1 t -
C
B)
c2 O P
2-16

L
-_____ ~.
MIL-HDBK-23A C H G N O T I C E 3 W 9999970 0147883 5 0 0 W

%
c
The c o r e modulus of e l a s t i c i t y E is again given by
C
h
C
l t - B
E = E P
C O h
C
1 t -
t
O
where I and A a r e the p r o p e r t i e s for a single row of c o r r u g a t i o n s defined

C C
previously .
The c o r e s h e a r modulus perpendicular to the d i r e c t i o n of the corrugation
flutes m a y again be e s t i m a t e d by the f o r m u l a
E t 3
O 0
G = S r ( h )
=Y o c
w h e r e the dimensions a r e shown i n the s k e t c h e s of f i g u r e s 2-21 and 2 - 2 2 the

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
p a r a m e t e r S m a y be r e a d f r o m the c h a r t s of f i g u r e s 2-21 and 2 - 2 2 , and other

quantities a r e as previously defined.
If the sandwich facings a r e d i s s i m i l a r , a good e s t i m a t e of the value of S

m a y be obtained by the methods d i s c u s s e d for sandwich having a single row
of c o r r u g a t i o n s .
2 . 3 ADHESIVES
In the fabrication of sandwich c o n s t r u c t i o n s , adhesives a r e used for bond-

ing facings t o c o r e and bonding between facings and fittings, reinforcing
p l a t e s , edge s t r i p s and other i n s e r t s . The adhesives used are r e s i n f o r m u -
lations e s p e c i a l l y developed to give high-strength bonds over a wide r a n g e of
e x p o s u r e and s t r e s s i n g conditions. Adhesives can be used to bond many
types of m e t a l i n highly s t r e s s e d applications. They can a l s o be formulated
t o have r e s i s t a n c e to m o d e r a t e l y elevated t e m p e r a t u r e s . The e v e r -expand-
ing advances i n c h e m i c a l d i s c o v e r y and application in the field of adhesives
p r e v e n t s a complete c u r r e n t p r e s e n t a t i o n , and v a r i o u s adhesive m a n u f a c t u r e r s
should be consulted or t h e i r recommendations and p r o p e r t i e s of adhesives
and p r o c e s s e s f o r any given application.
2-17 -
-------_ ------- a_

Adhesives of this type p r e s e n t l y a r e intended t o qualify f o r use i n a i r f r a m e s
under F e d e r a l Specification MMM-A- 132, Adhesives , Heat Resistant , A i r -
f r a m e S t r u c t u r a l , Metal to Metal ( r e f . 2-47). The evaluation t e s t s of that
specification utilizes s h e e t m e t a l lap-joint s p e c i m e n s . M i l i t a r y Specification
MIL-A-25463, Adhesive, Metallic, S t r u c t u r a l Sandwich Construction ( r e f . 2-37)
is used t o qualify an adhesive f o r c o r e - t o - f a c i n g bonds, and the r e q u i r e m e n t s
of Specification MMM-A- 132 a r e added for bonding complete sandwich con-
s t r u c t i o n , including s u c h p a r t s a s edge m e m b e r s , i n s e r t s , a t t a c h m e n t s , and
doublers.
2.3.1 Types
The metal-bonding adhesives can be c l a s s i f i e d into types by s e v e r a l

methods. T h e above specifications c l a s s i f y the adhesives by f o r m s u c h as
liquid, film, powder, o r s o l i d , and by the r e l a t i v e r e s i s t a n c e of the r e s u l t a n t
bonds t o elevated t e m p e r a t u r e e x p o s u r e . Frequently, t h e s e adhesives a r e
a l s o c l a s s i f i e d by g e n e r a l c h e m i c a l types and by the g e n e r a l r a n g e of curing
conditions r e c o m m e n d e d f o r use with the adhesive. Manufacturers now
c l a s s i f y t h e i r adhesives into g e n e r a l c h e m i c a l types with a wide v a r i a t i o n i n
the p r o p e r t i e s obtainable within e a c h type, depending on the m a t e r i a l and
formulation p r o c e d u r e s of the m a n u f a c t u r e r s . The metal-bonding adhesives
are c l a s s i f i e d i n this Handbook by c h e m i c a l type,with physical f o r m , curing
conditions , and s e r v i c e t e m p e r a t u r e a s subtypes.
2. 3. 1 . 1 Phenolic Resin Adhesives
One of the principal types of adhesives developed specifically for bonding

m e t a l s is based on phenolic r e s i n s modified with the e l a s t o m e r s neoprene
o r butadiene-acrylonitrile synthetic r u b b e r s , o r the polyvinyls.
2. 3. 1. 1. 1 Neoprene Elastomer-Phenolic. --One of the f i r s t s t r u c t u r a l

metal-bonding adhesives used i n this country in 1942 w a s a liquid f o r m u l a -
tion of phenol r e s i n and neoprene r u b b e r d i s p e r s e d in a suitable solvent.
The adhesive w a s f o r m u l a t e d to have a m i n i m u m of c r e e p . However, it
a l s o had l i t t l e flow during the bonding p r o c e s s and t h e r e f o r e the adhesive
had to be applied as a s m o o t h film, utilizing uniformly high p r e s s u r e s to
obtain contact over the e n t i r e bonding a r e a . This adhesive was f o r m u l a t e d
t o be c u r e d i n t h e r a n g e of 300" t o 335" F , and adhesives c u r e d within this
r a n g e are commonly r e f e r r e d to as being e l e v a t e d - t e m p e r a t u r e -setting.
2- 18
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-____ -~
4.
A t w o - s t e p adhesive p r o c e s s h a s been developed f o r use with this adhesive
i n bonding metal to wood o r t o low-density c o r e s that can be bonded with the
s y n t h e t i c - r e s i n woodworking adhesives. T h i s p r o c e s s p e r m i t s the final bond-
ing operation to be done at lower t e m p e r a t u r e s than is possible by d i r e c t
bonding with e l e v a t e d - t e m p e r a t u r e - s e t t i n g adhesives. F i r s t , the m e t a l -
bonding adhesive is applied to the m e t a l , and the f i l m c u r e d in a n oven with-
out p r e s s u r e a t t h e n o r m a l c u r e t e m p e r a t u r e . This adhesive coat on the
metal is then bonded to the wood o r t o the low-density c o r e using phenol o r
r e s o r c i n o l - r e s i n woodworking adhesives a t r o o m o r slightly elevated t e m p e r -
a t u r e s . T h i s m e t a l - p r i m e r principle has a l s o been used with o t h e r m e t a l -
bonding adhesives.
A m o r e r e c e n t formulation of this g e n e r a l type of adhesive has been the

development of a combination of neoprene, phenol, and nylon r e s i n s depos -
i t e d on a nylon o r g l a s s - f a b r i c cloth c a r r i e r . T h i s combination m a y be s u p -
plied as a single t a p e , as one liquid component t o be used with the t a p e , o r
as two liquid components t o be added on the c a r r i e r . T h i s adhesive h a s m u c h
b e t t e r flow during bonding than the o l d e r formulation, and c a n be used under
bonding p r e s s u r e s as low as 25 pounds p e r s q u a r e inch, as c o m p a r e d to
150 to 200 pounds p e r s q u a r e inch f o r the original-formulation.
T h e s e neoprene phenol adhesives a r e generally c l a s s i f i e d as having

m o d e r a t e s h e a r s t r e n g t h ( 2 , 5 0 0 t o 3 , 5 0 0 pounds p e r s q u a r e inch) in the s t a n d -
a r d 1 /2-inch aluminum lap-joint s p e c i m e n s at r o o m t e m p e r a t u r e s . T h e
s t r e n g t h of bonds m a d e to aluminum with t h e s e adhesives have been found to
d e t e r i o r a t e , i n s o m e i n s t a n c e s , when exposed to s a l t - w a t e r s p r a y o r high
humidity conditions. Adhesives of this type a r e generally being r e p l a c e d by
a c r y l o n i t r i l e -modified phenolic adhesives o r o t h e r s having i m p r o v e d p r o p e r t i e s .
2. 3. 1. 1. 2 N i t r i l e E l a s t o m e r - P h e n o l i c . --In the s e a r c h for adhesives

having b e t t e r r e s i s t a n c e to elevated t e m p e r a t u r e , numerous formulations
b a s e d on the combination of phenol r e s i n with butadiene-acrylonitrile s y n -
thetic r u b b e r have been developed. T h e s e adhesives a r e available as solvent
solutions, as unsupported films, and as films on nylon o r g l a s s - f a b r i c c a r r i e r .
S o m e of t h e s e formulations have good s t r e n g t h and aging p r o p e r t i e s a t t e m -
p e r a t u r e s t o 350" F and s h o r t i n t e r m i t t e n t e x p o s u r e at t e m p e r a t u r e s as high
as 5 0 0 " F m a y be possible. However, f o r many of the butadiene-acrylonitrile
phenolic a d h e s i v e s , the m a x i m u m d e s i g n t e m p e r a t u r e is 2 5 0 " to 260 F.
T h e s e adhesives usually have a s h e a r s t r e n g t h f r o m 2 , 8 0 0 to 4 , 6 0 0 pounds
p e r s q u a r e inch at r o o m t e m p e r a t u r e s i n the s t a n d a r d 1 / 2 - i n c h aluminum
lap-joint s p e c i m e n s .
2-19
-------
~-
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0147886 2 L T m
L
2. 3. 1 . 1. 3 Polyvinyl-Phenolic. --Shortly a f t e r the introduction i n this

country of the phenol-neoprene adhesives f o r high-strength bonding of m e t a l s ,
adhesives f o r bonding m e t a l s w e r e formulated f r o m combinations of phenol
r e s i n s with polyvinyl butyral, polyvinyl f o r m a l , o r other polyvinyl a c e t a l
r e s i n s . Originally, t h e s e polyvinyl phenolic adhesives w e r e found to have
p o o r e r s t r e n g t h p r o p e r t i e s and m o r e c r e e p i n the t e m p e r a t u r e r a n g e of 160"
to 200" F than the phenolic-neoprene a d h e s i v e s . However, with improved
formulations and c u r i n g p r o c e d u r e s , s o m e of the polyvinyl phenolic adhesives
c a n be used f o r designs exposed to t e m p e r a t u r e s a s high a s 250" F.
T h e s e adhesives a r e furnished in s e v e r a l f o r m s , s u c h a s solvent s o l u -

t i o n s , as solvent solutions with s e p a r a t e polyvinyl powder component, a s
unsupported films, and as films on nylon o r g l a s s - f a b r i c c a r r i e r .
Adhesives of this type a r e generally c l a s s i f i e d a s having high s h e a r

s t r e n g t h (4,100 to 5,100 pounds per s q u a r e inch) i n t h e s t a n d a r d 1 /2-inch aluminum
l a p joints at r o o m t e m p e r a t u r e . Bonds m a d e to aluminum with t h e s e adhe-
s i v e s have generally been found to be v e r y durable when exposed to s a l t -
water s p r a y o r high humidity conditions.
2. 3. 1 . 2 Epoxy Resin Adhesives
Extensive development of r e s i n adhesives based on synthetic r e s i n s f r o m

the condensation of epichlorohydrin and bisphenol, known a s epoxy r e s i n s ,
w a s s t a r t e d about 1947 i n t h i s country. T h e s e r e s i n s have good adhesion to
m e t a l s , g l a s s , p l a s t i c s , r u b b e r , and other m a t e r i a l s , even when used at
l o w bonding p r e s s u r e s . Typically, t h e s e epoxy ( o r a s s o m e t i m e s r e f e r r e d
t o a s epoxide) adhesive formulations a r e m a d e to be used at curing t e m p e r -
a t u r e s of 7 0 " to Z O O " F , which a r e m u c h lower than for other types of
metal-bonding adhesives. T h e s e adhesive formulations can be used without
adding solvents and have the advantage of curing without the evolution of
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volatile byproducts; t h e r e f o r e the volume s h r i n k a g e i s low.
Most of t'he e p o x y - r e s i n adhesives formulated for curing at the lower

t e m p e r a t u r e s a r e furnished i n viscous liquid f o r m with a s e p a r a t e liquid
curing agent. However, many d i f f e r e n t epoxy adhesive formulations a r e
available, including types f o r h i g h - t e m p e r a t u r e c u r i n g (260" t o 450" F )
and those that utilize s e p a r a t e s p e c i a l curing agents. T h e s e adhesives m a y
be supplied as one p a r t p a s t e , powder, f i l m s , o r as solid adhesives. Most
of the epoxy adhesives that c u r e at r o o m t e m p e r a t u r e s have the disadvantage
of a s h o r t pot life of l e s s than 2 h o u r s a f t e r the catalyst h a s been added to
the b a s e r e s i n .
2-20

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-___
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 9 7 0 0147887 156 9
T h e s e adhesives f o r m good f i l l e t s and bonds between facings and honeycomb

c o r e f o r sandwich construction. In addition t o use for fabrication of sandwich
and m e t a l - t o - m e t a l p a r t s , the epoxy-resin adhesives have proved to be of
s p e c i a l value i n the r e p a i r of sandwich constructions w h e r e it m a y not be con-
venient t o u s e e l e v a t e d - t e m p e r a t u r e and h i g h - p r e s s u r e curing conditions.
Modified formulations of the e p o x y - r e s i n adhesives a r e a l s o used for r e i n -
f o r c i n g and edging the c o r e s of sandwich panels.
Adhesives of this type generally have m o d e r a t e r o o m - t e m p e r a t u r e s h e a r

s t r e n g t h ( 3 , 100 to 3, 500 pounds p e r s q u a r e inch) i n t h e s t a n d a r d 1/2-inch
aluminum lap-joint s p e c i m e n s . T h e r e have been s o m e indications that t h e s e
adhesives a r e not as d u r a b l e i n bonds to aluminum when exposed t o s a l t -
w a t e r s p r a y , high humidity, o r weathering conditions as a r e s o m e other types
of metal-bonding adhesives ( r e f . 2 - 6 , 2-7). The durability c a n be i m p r o v e d
i f t h e a s s e m b l i e s a r e p r o t e c t e d with one coat of zinc c h r o m a t e p r i m e r and
two coats of aluminized l a c q u e r . T h e s e a d h e s i v e s , as usually f o r m u l a t e d ,
do not have good peel r e s i s t a n c e , and the types formulated for c u r i n g at the
lower t e m p e r a t u r e s a l s o show poor c r e e p r e s i s t a n c e a t t e m p e r a t u r e s of
180" t o 200" F. T h e p e r f o r m a n c e of t h e s e adhesives i n m o i s t u r e and peel
r e s i s t a n c e can be i m p r o v e d by using c u r e d p r i m e c o a t s of other m e t a l -
bonding adhesives on the m e t a l p r i o r to bonding. C e r t a i n synthetic r u b b e r
m a t e r i a l s , s u c h as polysulfide e l a s t o m e r s , c a n a l s o be added to the epoxy-
r e s i n adhesives to i m p r o v e the peel r e s i s t a n c e . However, the addition of
t h e s e plasticizing m a t e r i a l s a l s o i n c r e a s e s the c r e e p tendencies of the adhe-
s i v e and l o w e r s heat r e s i s t a n c e . E p o x y - r e s i n adhesives f o r m u l a t e d for
e l e v a t e d - t e m p e r a t u r e c u r i n g (325" F ) have been r e p o r t e d by t h e i r m a n u -
f a c t u r e r s to have good s t r e n g t h p r o p e r t i e s at t e m p e r a t u r e s as high a s 350" F
and a l s o show b e t t e r weathering and s a l t - w a t e r s p r a y r e s i s t a n c e . The use
of t h e s e higher curing t e m p e r a t u r e s m u s t , however, be used with caution s o
as not to r e d u c e the s t r e n g t h of facing m a t e r i a l s .
2. 3. 1. 2. 1 Epoxy-Phenolic--Formulations including both epoxy r e s i n s

and phenol r e s i n s have good s t r e n g t h at elevated t e m p e r a t u r e s . Adhesives of
t h i s type'may be i n liquid f o r m but a r e usually supplied as films supported on
a w i d e - m e s h g l a s s f a b r i c . Film t h i c k n e s s e s of O. 008 to 0:012 inch a r e avail-
able f o r m e t a l - t o - m e t a l bonding and O. 012 to O. 030 inch for honeycomb s a n d -
wich fabrication. When used f o r bonding s t a n d a r d 1 /2-inch aluminum lap-joint
s p e c i m e n s , t h e s e adhesives n o r m a l l y have a r o o m - t e m p e r a t u r e s h e a r s t r e n g t h
of f r o m 3 , 100 t o 3 , 8 0 0 pounds p e r s q u a r e inch. However, c o m p a r e d to other
available t y p e s , t h e i r s t r e n g t h at 450" to 500" F is v e r y good, being in the
r a n g e of 1 , 4 0 0 to 1 , 8 0 0 pounds p e r s q u a r e inch. A s t r e n g t h of approximately
1 , 0 0 0 pounds p e r s q u a r e inch is obtained a f t e r aging of aluminum s p e c i m e n s
f o r 192 t o 200 h o u r s at 500" F , When used f o r bonding s t a i n l e s s steel, the
aging p r o p e r t i e s at 500" F of t h i s and a l l other conventional types of h e a t -
r e s i s t a n t adhesives have generally been p o o r , but they do have good s t r e n g t h s
at t e m p e r a t u r e s up t o 400" F.
2-21
__----------------
i
Provided by IHS
-- .. i -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-___~___ -~ ___
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 OLY7 O92
The s t o r a g e life of t h i s type of phenol-epoxy r e s i n tape adhesive is r a t h e r

limited, normally being 24 to 36 hours at r o o m t e m p e r a t u r e s , 1 month at
40" F , and 3 t o 6 months at O " F.
2. 3. 1. 2. 2 Epoxy-Polyamide. --Brought to c o m m e r c i a l availability about

1960, this c h e m i c a l classification of unsupported film has r e c e i v e d wide -
s p r e a d application in a i r c r a f t a s s e m b l i e s of both the m e t a l - t o - m e t a l and
sandwich construction t y p e s . It f e a t u r e s exceptionally high s h e a r (lap-joint
s t r e n g t h of 5, 600 t o 6 , 7 0 0 pounds p e r s q u a r e inch) and peel s t r e n g t h s and
general toughness, as well as a forgiving n a t u r e with r e s p e c t to s u r f a c e
preparation. Reputedly s t r e n g t h s a r e significantly reduced as a r e s u l t of
extended high humidity o r water i m m e r s i o n exposure. Rated s e r v i c e t e m -
p e r a t u r e r a n g e is -423" to +180" F. P r o c e s s i n g is s i m p l e l a r g e l y because
of the m a t e r i a l ' s unique s u r f a c e tension c h a r a c t e r i s t i c s ; c u r e p r e s s u r e s of
5 to 50 pounds per s q u a r e inch and c u r e t e m p e r a t u r e s of 310" t o 360 O F
are used. Storage life is good. The m a t e r i a l is available i n s e v e r a l weights
o r thicknesses and a l s o c a n be p r o c u r e d i n a supported f o r m .
Allied but different f o r m u l a t i o n s of epoxy and polyamide r e s i n s a r e a v a i l -

able as two-part liquids o r p a s t e s but a r e not generally used f o r sandwich
construction d e s p i t e t h e i r ability to c u r e at t e m p e r a t u r e s between 75" and
180" F.
2. 3. 1.2. 3 Modified Epoxy R e s i n , Low T e m p e r a t u r e Curing. --Motivated

by a i r f r a m e m a n u f a c t u r e r s ' d e s i r e to avoid reduction in design allowables
of s o m e aluminum alloy facing m a t e r i a l a s a r e s u l t of 350" F adhesive c u r e
t e m p e r a t u r e , m o s t m a j o r adhesive m a n u f a c t u r e r s have been supplying,
s i n c e 1965, a supported film m a t e r i a l which c u r e s at a nominal 250" F for
1 hour. This c h e m i c a l c l a s s i f i c a t i o n c a n in m o s t i n s t a n c e s be c u r e d a s low
as 180" F o r a s high as 350" F (for production speed) under 10 t o 50 pounds
p e r s q u a r e inchsand exhibits high s h e a r s t r e n g t h (lap-joint s t r e n g t h of
4 , 0 0 0 to 5 , 9 0 0 pounds p e r s q u a r e inch) and good peel s t r e n g t h over the s e r v i c e
t e m p e r a t u r e r a n g e of -65" to t 180" F. The m a t e r i a l is available in s e v e r a l
weights o r t h i c k n e s s e s , m o s t often with a synthetic r a n d o m m a t c a r r i e r .
Refrigerated s t o r a g e is mandatory with open t i m e at ambient t e m p e r a t u r e s
limited t o a f e w d a y s .
2. 3. I , 3 P o l y a r o m a t i c R e s i n Adhesives
T h r e e b a s i c types of heterocyclic p o l y m e r s h a v e recently been brought to

c o m m e r c i a l availability in the f o r m of supported adhesive film and p r e -
impregnated g l a s s f a b r i c f o r laminated sandwich f a c i n g s . A s a r e s u l t , a new
c l a s s of s t r u c t u r a l m a t e r i a l capable of r e s i s t i n g t e m p e r a t u r e s up to 1000" F
is in a w e l l advanced development s t a t u s with s e v e r a l other c h e m i c a l types
under active l a b o r a t o r y s c a l e development. The t h r e e types a r e :
2-22
--- --
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_-__ __
=
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MIL-HBBK-23A CFIG NOTICE 3 9 9 9 9 9 7 0 0147887 T 2 9
( i ) Polybenzimidazole (PBI) - - r e a c t i o n product of a t e t r a i m i n e and a

bisphenylester. It provides bond s t r e n g t h s c o m p a r a b l e to the epoxy-phenolic
r e s i n adhesives in the r a n g e of -423" to 1000" F ( f o r s h o r t t e r m ) but m u c h
improved t h e r m a l stability a f t e r m o d e r a t e l y extended e x p o s u r e s t o elevated
t e m p e r a t u r e s . Significant degradation of s t r e n g t h s o c c u r s a f t e r 500 hours
a t 500" F and 50 h o u r s at 600" F. C u r e t e m p e r a t u r e is about 600" F and
extended p o s t c u r e in an i n e r t a t m o s p h e r e through the design t e m p e r a t u r e
is usually n e c e s s a r y .
(2) Polyimide ( P I ) - - r e a c t i o n product of a diamine and a dianhydride.

This c l a s s of adhesive h a s the outstanding t h e r m a l stability of the PBI type
an& a l m o s t c o m p a r a b l e bond s t r e n g t h s but s u p e r i o r r e s i s t a n c e to oxidation.
They a r e generally r a t e d f o r m e d i u m t o l o n g - t e r m s e r v i c e i n the r a n g e of
400" t o 600" F as well as down to -320" F. C u r e t e m p e r a t u r e m a y be as
low as 350" F but g e n e r a l l y is 500" F o r the design t e m p e r a t u r e . P o s t -
c u r e is usually not n e c e s s a r y . C u r e p r e s s u r e s m a y be as low as 40 pounds
p e r s q u a r e inch.
W h e r e e x t r e m e l y long-term t h e r m a l stability is a r e q u i r e m e n t , polyimide-

based adhesives have been developed t h a t a r e suitable for s t r u c t u r a l applica-
tions. They exhibit r o o m t e m p e r a t u r e l a p - s h e a r s t r e n g t h s of approximately
3,400 pounds p e r s q u a r e inch on titanium and r e t a i n s t r e n g t h s of approximately
2,000 pounds p e r s q u a r e inch when t e s t e d at 500" F , even a f t e r s e v e r a l
thousand hours at 500" F. T h e s e adhesives generally contain a n a r s e n i c -
based anti-oxidant that d e g r a d e s rapidly at 600" F. The uncured adhesive
is e x t r e m e l y s e n s i t i v e to humidity and should not be exposed to r e l a t i v e
humidity i n e x c e s s of 30 p e r c e n t d u r i n g p r o c e s s i n g .
(3) Polyimide -Polyamide Copolymer - -This c l a s s of adhesive i s e s s e n t i a l l y

comparable i n p e r f o r m a n c e t o the PI type but i s , as of e a r l y 1967, i n a less
developed s t a t u s .
A l l t h r e e types of adhesives evolve 9 t o 16 p e r c e n t condensation products

(chiefly w a t e r and r e s i d u a l pyridene solvent) d u r i n g c u r e . T h u s , it is often
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n e c e s s a r y t o employ augmented v a c u u m bag o r p r e s s p r e s s u r e s of about
200 pounds p e r s q u a r e inch to achieve r e l i a b l e high-strength bonds with
m e t a l - t o - m e t a l ( s t a i n l e s s s t e e l and titanium alloys) joints. T h i s is not as
feasible with c o r e which m a y c r u s h a t s u c h c u r e p r e s s u r e s . P o r o s i t y of
bands r e s u l t i n g f r o m the evolved volatiles a n d / o r low c u r e p r e s s u r e s
i n c r e a s e the probability of a t m o s p h e r i c m o i s t u r e penetration along the g l a s s
f i b e r s of the c a r r i e r f a b r i c , a condition making f o r s t r e n g t h degradation
during s e r v i c e . Accordingly c a r e f u l attention m u s t be given t o the p r o c e s s -
ing techniques.
2-23
.___I__-

~- ._ ~
2 . 3 . L. 4 Inorganic Adhesives
H e a t - r e s i s t a n t c e r a m i c m a t e r i a l s have been investigated f o r use as

adhesives i n m e t a l - t o - m e t a l bonding, b e c a u s e of the need f o r adhesives c a p -
a b l e of maintaining t h e i r s t r e n g t h a t elevated t e m p e r a t u r e s up t o and above
1000" F. C e r a m i c - t y p e a d h e s i v e s , when p r e p a r e d and applied to m e t a l in
a manner similar t o application of porcelain e n a m e l o r c e r a m i c coatings,
can develop l a p - s h e a r s t r e n g t h s of 1 , 5 0 0 pounds p e r s q u a r e inch and higher
on precipitation-hardened 17-7PH s t a i n l e s s s t e e l at 1000" F. The t h e r m a l
expansion of the c e r a m i c adhesive should approach that of the m e t a l , but not
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exceed it, i n o r d e r to obtain m a x i m u m s h e a r s t r e n g t h s . In other w o r d s , the
c e r a m i c should always be held slightly in c o m p r e s s i o n . If the coefficient of
expansion of the c e r a m i c is g r e a t e r than that of the m e t a l , c r a z i n g w i l l
deveop and the bond could d e s t r o y i t s e l f . The addition of fine m e t a l pow-
d e r s , r e s u l t i n g in a c e m e n t , have been found to i m p r o v e impact and t h e r m a l
shock r e s i s t a n c e and r e d u c e b r i t t l e n e s s . The incorporation of v e r y fine m e t a l
s c r e e n o r thin m e t a l f i b e r m a t s into the bond a s c a r r i e r s a l s o i m p r o v e s the
bond. The c e r a m i c adhesives havs a u s e t e m p e r a t u r e about two-thirds of the
application t e m p e r a t u r e . Curing f u r n a c e s do not r e q u i r e i n e r t a t m o s p h e r e s ,
as in the c a s e f o r b r a z e s . In f a c t , the oxygen content of the a i r s e e m s to
i m p r o v e the bond.
2 . 3 . 2 Available S o u r c e s
T h e t r a d e n a m e s and m n u f a c t u r e r s of s t r u c t u r a l adhesives suitable for

sandwich and m e t a l bonding c a n be obtained f r o m qualified products l i s t s for
U. S . M i l i t a r y Specification M I L - A - 2 5 4 6 3 o r F e d e r a l Specification M M M - A - 132
(ref. 2 - 3 7 , 2-47).
2 . 3 . 3 Forms
~ ~~~~
T h e adhesives a r e supplied i n a v a r i e t y of f o r m s . Some of the adhesives

are f u r n i s h e d a s solvent solutions of the r e s i n , ranging f r o m 8 to 30 p e r c e n t
by weight of r e s i n s o l i d s . The epoxy r e s i n adhesives a r e frequently supplied
as thick viscous liquids of which the r e s i n is a l m o s t 100 p e r c e n t chemically
r e a c t i v e , but contains v a r i o u s proportions of f i l l e r s . Some of the epoxy
r e s i n s are a l s o supplied as solid powders o r s t i c k s .
2-24

- -
MIL-HDBK-23A CHG N O T I C E 3 9999970 0147891 b 7
Adhesives are. a l s o f u r n i s h e d i n t h e f o r m of unsupported films f o r m e t a l

bonding, o r as t a p e s with the adhesive supported on wide-mesh nylon o r glass-
f a b r i c s c r i m cloth f o r bonding sandwich constructions. Films o r tape adhe-
s i v e s have generally been used t o simplify the operation of applying the adhe-
s i v e and r e d u c e p r o b l e m s i n s p r e a d i n g and removing solvents. Also, the
f i l m s with s c r i m cloth c a r r i e r s usually have g r e a t e r peel r e s i s t a n c e b e c a u s e
of the addition of the cloth, which aids i n the formation of s a t i s f a c t o r y f i l l e t s .
Composite films have a l s o been devised wherein one s i d e of a s c r i m cloth
h a s a fillet-forming adhesive for bonding t o honeycomb c o r e s and the other
s i d e of the s c r i m h a s a s t a n d a r d metal-bonding adhesive.
Many adhesives a r e supplied as a o n e - p a r t s y s t e m . However, with s o m e

adhesives it is n e c e s s a r y t o add a s e p a r a t e c a t a l y s t to the r e s i n p r i o r to use.
With one of the polyvinyl-phenolic r e s i n a d h e s i v e s , the s y s t e m is supplied i n
two p a r t s with a liquid phenol r e s i n and vinyl powder that is s p r i n k l e d into
the liquid r e s i n a f t e r spreading. S e p a r a t e liquid adhesive p r i m e r s a r e a l s o
r e q u i r e d f o r use on the m e t a l facings o r c o r e with s o m e of the film and tape
adhesive s .
2. 3.4 ' S t o r a g e and Mixing of Adhesives
W h i l e s o m e of the adhesives for sandwich and metal bonding c a n be s t o r e d

f o r long periods a t r o o m t e m p e r a t u r e , m a n u f a c t u r e r s usually r e c o m m e n d
s t o r a g e a t lower t e m p e r a t u r e s of O" to 50" F o r lower t o prolong adhesive
life. At t h e s e t e m p e r a t u r e s the s t o r a g e life of many adhesives w i l l v a r y
f r o m 6 months to s e v e r a l y e a r s , depending upon the type. S o m e of the adhe-
s i v e s formulated for elevated t e m p e r a t u r e r e s i s t a n c e have even s h o r t e r l i f e ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
and these adhesives a r e usually shipped i n d r y i c e and should be s t o r e d at O "

to 32" F. The r e l a t i v e stability of adhesives during s t o r a g e c a n be d e t e r m i n e d
by making periodic t e s t s s u c h as d e s c r i b e d i n Military Specification MIL-A-9067
( r e f . 2-36). This specification r e q u i r e s that no adhesive s a m p l e s h a l l be used
for production bonding that has not been t e s t e d for quality within 96 h o u r s of
use.
Many of the adhesives are s e n s i t i v e to the p r e s e n c e of m o i s t u r e . Liquid

adhesives should be s t o r e d i n cans with tightly fitting c o v e r s and films should
be tightly wrapped i n a suitable protective film. C a r e should be taken to
prevent contamination of the adhesive with condensed m o i s t u r e when the
adhesive is r e m o v e d f r o m cold s t o r a g e . Cans o r films taken f r o m cold s t o r -
age should be p e r m i t t e d , i f possible, to w a r m t o r o o m t e m p e r a t u r e s before
being opened. E a c h container should be of s u c h s i z e that i t holds no m o r e
than c m be used during the n o r m a l s t o r a g e life of the adhesive at r o o m t e m -
p e r a t u r e . Adhesives that a r e s e n s i t i v e t o m o i s t u r e should not be r e t u r n e d
t o cold s t o r a g e i n p a r t i a l l y filled containers.
2-25 .~
I-
Some adhesives a r e supplied as o n e - p a r t adhesives and r e q u i r e only
thorough s t i r r i n g before being r e a d y to use. Frequently, the v i s c o s i t y of the
adhesive as r e c e i v e d w i l l be too g r e a t f o r p r o p e r application. The m a n u -
f a c t u r e r ' s recommendation as to the p r o p e r method of thinning should be
closely followed. The solvents f o r u s e with t h e s e adhesives a r e usually c a r e -
fully f o r m u l a t e d by t h e m a n u f a c t u r e r t o i n s u r e l o n g - t e r m compatibility of the
s o l i d s , p r o p e r flow, a s s e m b l y , and curing r e q u i r e m e n t s .
2.3.5 Strength of Adhesive Bonds
The i n t r i n s i c e l a s t i c p r o p e r t i e s and s t r e n g t h of adhesives have not been

evaluated to any g r e a t extent, probably because design information for adhesive-
bonded joints, wherein t h e s e p r o p e r t i e s could be used, have not been d e r i v e d ,
However, s e v e r a l types of adhesives have been evaluated i n bond l i n e s
between ends of aluminum tubes by t o r s i o n and tension t e s t s ( r e f . 2-18).
P r o p e r t i e s d e t e r m i n e d a r e given in table 2-7 f o r p u r p o s e s of c o m p a r i s o n of
the e l a s t i c p r o p e r t i e s and s t r e n g t h of the adhesive types and possible i n c l u -
sion i n f u t u r e designs f o r specific joints.
2.3.5. 1 Lap-Joint Strength Data -_
A l a r g e amount of d a t a h a s been obtained on the s t r e n g t h of a d h e s i v e -

bonded l a p joints between m e t a l adherends. T h e s e d a t a a r e useful f o r d e t e r -
mining effects of environmental conditions on s u c h joints and c a n f u r n i s h
guidelines f o r the design of m e t a l - t o - m e t a l joints i n sandwich s u c h as occur
at edgings and i n s e r t s . The r e s u l t s of the lap-joint t e s t s a r e usually e x p r e s s e d
as s h e a r s t r e n g t h values b a s e d on t h e load divided by the a r e a of the lap.
Studies of lap-joint s t r e s s e s ( r e f . 2 - 9 and 2-18) have shown that s h e a r s t r e s s
distribution is dependent upon adhesive p r o p e r t i e s and thickness a s well as
lap-joint dimensions. N o r m a l s t r e s s e s a r e a l s o developed i n l a p joints and,
w h i l e t h e s e s t r e s s e s could initiate t e n s i l e f a i l u r e , they a r e usually not con-
s i d e r e d b e c a u s e of complications of a n a l y s i s . Despite t h e s e a n o m a l i s m s the
s t a n d a r d of c o m p a r i s o n f o r m e t a l - t o - m e t a l bonds has been the lap-joint
specimen with' adherends of O. 063-inch aluminum alloy s h e e t s bonded i n
1/2-inch o v e r l a p ( r e f . 2-47). The adhesive s h e a r s t r e n g t h s produced by
tests of t h i s type of s p e c i m e n cannot be used as a value f o r design, even i f
the designs utilize the same m a t e r i a l s , b e c a u s e of an " L / t effect". If L is
the length of o v e r l a p i n a bonded joint and t is adherend t h i c k n e s s , then the
apparent s h e a r s t r e n g t h s of adhesives a r e nonlinear functions of L / t and
d e c r e a s e as t h e L / t r a t i o i n c r e a s e s . The L / t r a t i o of the s t a n d a r d lap-joint
specimen is approximately 8. O and, i f a potential design utilized the apparent
s h e a r s t r e n g t h produced by t e s t s of the s t a n d a r d s p e c i m e n f o r an L / t g r e a t e r
than 8. O, the r e s u l t i n g bonded joint m a y not be conservative. T h e dependence
of a v e r a g e lap-joint s h e a r s t r e s s on r a t i o of l a p length t o adherend thickness
is shown i n f i g u r e 2-23. The c u r v e s a r e based on t h e o r e t i c a l analyses and
p r o p e r t i e s of two types of adhesives i n l a p joints of aluminum ( r e f . 2-9, 2-18).
L
2-26
_- ...-
e
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-- ~-
MIL-HDBK-23A CHG N O T I C E 3 m 9 7 9 9 7 7 0 0347893 4 5 T m
A s u m m a r y of s t a n d a r d lap-joint s t r e n g t h d a t a for s e v e r a l types of adhesives

is given i n t a b l e 2-8. Included a r e d a t a on effects of environmental conditions
s u c h as t e m p e r a t u r e , c h e m i c a l , and wet exposure. The r e s u l t s of the l a p -
joint tests v a r y g r e a t l y according to t h e m a t e r i a l selection, configuration of
s p e c i m e n , bonding conditions, and evaluation environment. T h e r e f o r e , t e s t
r e s u l t s m u s t be judiciously c o n s i d e r e d when selecting an adhesive for a bond-
ing p r o c e s s . F o r example, i n r o o m - t e m p e r a t u r e t e s t s of adhesives using
t h e s t a n d a r d lap-joint s p e c i m e n , one adhesive might have a n a v e r a g e l a p -
joint s t r e n g t h of 3 , 200 pounds p e r s q u a r e i n c h , and another a lap-joint s t r e n g t h
of 3 , 7 0 0 pounds p e r s q u a r e inch as c o m p a r e d to the specification r e q u i r e m e n t s
of 2,500 pounds p e r s q u a r e inch. T h e r e would be l i t t l e difference in the choice
of t h e s e a d h e s i v e s , f r o m the standpoint of design, and t h e r e f o r e , final s e l e c -
tion would probably depend on the r e s u l t s of other p r o p e r t y t e s t s i n which
i m p o r t a n t d i f f e r e n c e s could be obtained between adhesives.
2. 3.5. 2 Strength of Adhesives i n Sandwich

with Honeycomb C o r e s
Lap-joint s t r e n g t h d a t a a r e not c o n s i d e r e d of p r i m e use for d e t e r m i n i n g

adequacy of adhesives for bonding sandwich facings to honeycomb c o r e s . The
need of a n adhesive t o f o r m s t r o n g fillets at the ends of the c o r e c e l l s to
produce s a t i s f a c t o r y sandwich h a s prompted the evaluation of peel s t r e n g t h
and sandwich flatwise t e n s i l e s t r e n g t h ( r e f . 2-37). P e e l s t r e n g t h is d e t e r -
mined as the t o r q u e n e c e s s a r y t o peel a facing f r o m a sandwich c o r e . Data
f o r s e v e r a l typical adhesives a r e given in table 2 - 9 . The sandwich flatwise
t e n s i l e s t r e n g t h d a t a have been converted to fillet s t r e n g t h in pounds p e r inch
of fillet length s o that flatwise t e n s i l e s t r e n g t h of sandwich with c o r e s of any
c e l l s i z e c a n be e s t i m a t e d . The fillet length for c o r e s of hexagonal o r s q u a r e
c e l l s is d e t e r m i n e d by dividing 4 by the c e l l s i z e ( 4 / s ) ( r e f . 2-29). Thus
the sandwich t e n s i l e s t r e n g t h a t f a c i n g - t o - c o r e bond f a i l u r e is given by the
for mula
4
Sandwich flatwise t e n s i l e s t r e n g t h = -
S
X (fillet strength)
w h e r e s is c o r e c e l l s i z e .
2-27
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HBBK-23A C H G N O T I C E 3 H 9 9 9 9 9 7 0 0347874 396 m
REFERENCED DOCUMENTS
BJORKSTEN, J. , E L L I O T T , J . C. , and ROTH, R. J.

1952. F o a m e d M e t a l Low -Density C o r e M a t e r i a l f o r Sandwich
Construction. Wright A i r Develop. C e n t e r T e c h . Rep. 52-51.
CADY, W. M. , e t al
1948. R a d a r S c a n n e r s and Radomes. M a s s . I n s t . T e c h n o l . , Radi-
ation Lab. Series, Vol. 26, McCraw-Hill Book Co. , N. Y .
CAMPACNA, P. J., PRESTON, H. M . , and WAHL, N. E.

-
1 9 54. Development of He at - Re sis t ant F o a m e d -In P l a c e Di e l e c t r i c
C o r e M a t e r i a l s f o r Sandwich Radomes. Wright A i r Develop.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C e n t e r Tech. Rep. 54-249.
DOYLE, D. V . , a n d D R O W , J. T.
1946. T h e E l a s t i c P r o p e r t i e s of Wood, Y o u n g ' s Moduli, Moduli of
Rigidity, and P o i s s o n ' s Ratios of Mahogany and Khaya.
U.S. F o r e s t P r o d . Lab. Rep. 1528-C.
DOYLE, D. V. , DROW, J. T. , and McBURNEY, R. S.

1945. T h e E l a s t i c P r o p e r t i e s of Wood--The Y o u n g ' s Moduli, Moduli
of Rigidity, and P o i s s o n ' s Ratios of B a l s a and Quipo.
U.S. F o r e s t P r o d . Lab. Rep. 1528.
EICKNER, H. W .
1957. Weathering of Adhesive -Bonded L a p Joints of Clad Aluminum
Alloy. Wright A i r Develop. C e n t e r Tech. Rep. 54-447, P a r t II.
EICKNER, H. W .
1955. Weathering of Adhesive -Bonded L a p J o i n t s of Clad Aluminum
Alloy. Wright A i r Develop. C e n t e r T e c h . Rep. 54-447, P a r t I.
FAHEY, D. J . , SETTERHOLM, V. C. , SEIDL, R. J . , and

KUENZI, E. W .
1956. P a p e r Honeycomb C o r e f o r M a r i n e Applications.
U. S. F o r e s t P r o d . L a b . Rep. t o BuShips.
COLAND, M . , and REISSNER, E.

1944. S t r e s s i n Cemented J o i n t s . J o u r n a l of Applied L s c h a n i c s .
2 -28

MIL-HDBK-23A C H G N O T I C E 3 H 9999970 0347895 222
(2-10) HEEBINK; B. C., KOMMERS, W. J., and MOHAUPT, A . A.

1950. Durability of Low -Density C o r e M a t e r i a l s and Sandwich P a n e l s
of t h e A i r c r a f t Type as D e t e r m i n e d by L a b o r a t o r y T e s t s and
ExDosure t o the W e a t h e r , P a r t III. U.S. F o r e s t P r o d . Lab.
~~ ~
Rep, 1573-B.
( 2 - 11) JENKINSON, P. M.
1965. Effect of C o r e T h i c k n e s s and M o i s t u r e Content on Mechanical
P r o p e r t i e s of Two R e s i n - T r e a t e d P a p e r Honeycorrib C o r e s .
U.S. F o r e s t S e r v . R e s e a r c h P a p e r FPL 35, F o r e s t P r o d .
L a b . , Madison, W i s .
(2-12) JENKINSON, P. M . , FAHEY, D. J . , KUTSCHA, D. F . , and

KUENZI, E. W.
1961. Effect of C o r e T h i c k n e s s on C o m p r e s s i o n P r o p e r t i e s of R e s i n -
T r e a t e d P a p e r Honeycomb C o r e . U.S. F o r e s t P r o d . Lab.
Rep. SANDIA 2.
(2-13) JENKINSON, P. M . , and KUENZI, E. W.

1962. Effect of C o r e T h i c k n e s s on S h e a r P r o p e r t i e s of Aluminum
Honeycomb C o r e . U.S. F o r e s t P r o d . L a b . Rep. 1886.
(2-14) JENKINSON, P. M . , and KUENZI, E. W .

1962, F a t i g u e P r o p e r t i e s of Some Aluminum and S t a i n l e s s S t e e l
Sandwich C o n s t r u c t i o n s . ASD-TDR-62- 1003.
(2-15) JENKINSON, P. M . , and KUENZI, E. W .

1957. Mechanical P r o p e r t i e s of 422-5 Bacfoam C o r e for Sandwich
Construction. Wright A i r Develop. C e n t e r T e c h . Rep. 57-1 32.
( A s t i a Doc. No. AD 118249).
(2- 16) JENKINSON, P. M . , and KUENZI, E. W.
1957. P r o p e r t i e s of Alkyd-Isocyanate F o a m e d - I n - P l a c e C o r e .
Wright A i r Develop. C e n t e r T e c h . Rep. 57-182.
( A s t i a Doc. No. 155884).
(2-17) KREITH, F.
1960. P r i n c i p l e s of Heat T r a n s f e r . I n t e r n a t i o n a l Textbook Co. ,
S c r a n t o n , Pa.
(2-18) KUENZI, EDWARD W . , and STEVENS, GORDON H.

1963. D e t e r m i n a t i o n of Mechanical P r o p e r t i e s of Adhesives f o r
U s e i n t h e Design of Bonded J o i n t s . U. S. F o r e s t S e r v i c e
R e s e a r c h Note FPL-Oll. F o r e s t P r o d , L a b . , Madison, W i s .
2 -29
..
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__ _ _ - _ _ ~ ~
MIL-HDBK-23A CHG N O T I C E 3 99'79970 OL4789b L b 9
(2-19) KUENZI, E. W.
1955. Mechanical P r o p e r t i e s of Aluminum Honeycomb C o r e s . U. S .
Forest P r o d . Lab. Rep. 1849.
(2-20) KUENZI, E. W.
1949. Effect of Elevated T e m p e r a t u r e s on the Strengths of S m a l l
Specimens of Sandwich Construction of t h e A i r c r a f t T y p e - -
T e s t s Conducted I m m e d i a t e l y After the T e s t T e m p e r a t u r e
W a s Reached. U.S. F o r e s t P r o d . Lab. Rep. 1804.
(2-21) LIBOVE, C . , andHUBKA, R. E.

1951. E l a s t i c Constants f o r C o r r u g a t e d - C o r e Sandwich Plates.
NACA Tech. Note 2289.
(2-22) McCOWN, J. W . , BARRETT, W . F . , and NORTON, A . M.

Design and T e s t i n g of a Hot Redundant S t r u c t u r e s Concept f o r
a Hypersonic Flight Vehicle. M a r t i n - M a r i e t t a CorD. .
B a l t i m o r e , Md.
(2-23) NATIONAL DEFENSE RESEARCH COMMITTEE

1951. T a b l e s of D i e l e c t r i c M a t e r i a l s . Vols. I and II, Lab. f o r
Insulation R e s . , M a s s . Inst. Technol.
(2-24) O ' B R I E N , F. R . , and OGLESBY, S . , J R .

1955. Investigation of T h e r m a l P r o p e r t i e s of Plastic Laminates,
C o r e , and Sandwich P a n e l s . Wright A i r Develop. C e n t e r t
T e c h . Rep. 54-306, P a r t 2.
(2-25) SAPOWITH, A. D.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
1959. T r a n s v e r s e S h e a r S t i f f n e s s f o r t.he Double "V" C o r r u g a t e d -
C o r e Sandwich P a n e l . A e r o / S p a c e Eng. pp. 53-56, Sept.
(2-26) SETTERHOLM, V. C . , HEEBINK, B. G . , andKUENZ1, E. W .

1955. . Durability of Low-Density Sandwich P a n e l s of t h e A i r c r a f t
Type as D e t e r m i n e d by L a b o r a t o r y T e s t s and E x p o s u r e to
W e a t h e r . U.S. F o r e s t P r o d . Lab. Rep. 1573-C.
(2-27) SETTERHOLM, V. C . , a n d K U E N Z I , E. W .
1956. Effect of M o i s t u r e Sorption on Weight and Dimensional
Stability of Alkyd-Isocyanate F o a m C o r e . Wright A i r Develop.
C e n t e r T e c h . Rep. 56-86.
2 -30
-- __

\
t (2-28) SETTERHOLM, V. C . , and KUENZI, E. W .
1956. P e r f o r m a n c e of Sandwich with C o r e s of F o a m e d Silicone and
I -
Modified P o l v e s t e r R e s i n s at Elevated T e m n e r a t u r e s and

H i g h H u m i d i t y . Wright A i r Develop. C e n t e r T e c h . Rep.
56-230. ( A s t i a Doc. No. AD 110421).
(2-29) SETTERHOLM, V. C. , EICKNER, H. W. , and KUENZI, EDWARD W.

1956. T e n s i l e S t r e n g t h of Adhesive Bonds i n Sandwich with Aluminum
F a c i n g s and Aluminum Honeycomb C o r e s Wright A i r Develop. a
C e n t e r T e c h . Rep. 56-239.
(2-30) SWANN, R. T . , and PITTMAN, C. M.

1961 Analysis of Effective T h e r m a l Conductivities of Honeycomb-
o
C o r e and C o r r u g a t e d - C o r e Sandwich P a n e l s . NASA T e c h .

Note D714.
(2-31) U.S. AIR FORCE-NAVY

1948. Radome E n g i n e e r i n g Manual. A i r M a t e r i e l Command Manual
NO. 80-4, NAVER 16-45-502.
I (2-32) U. S. DEPARTMENT O F DEFENSE

1951. Design of Wood A i r c r a f t S t r u c t u r e s . A i r F o r c e , Navy,
C o m m e r c e Bulletin 18. 2nd ed. Munitions B o a r d A i r c r a f t
Comm.
(2-33) U. S. DEPARTMENT O F DEFENSE

1951. Wood A i r c r a f t Inspection and F a b r i c a t i o n . A i r F o r c e , Navy,
C o m m e r c e Bulletin 19. Munitions B o a r d A i r c r a f t Comm.
(2-34) U.S. DEPARTMENT O F DEFENSE

Current P l a s t i c s f o r Flight Vehicles: Part I, Reinforced Plastics e
M i l i t a r y Handbook 17. A r m e d F o r c e s Supply Support C e n t e r .

Available f r o m U. S. Cov. P r i n t i n g Office, Washington, D. C.

Current, M e t a l l i c M a t e r i a l s and E l e m e n t s for A e r o s p a c e Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U. S . Gov.
P r i n t i n g Office , Washington, D. C.

Current Adhesive Bonding, P r o c e s s and Inspection R e q u i r e m e n t s f o r .
M i l i t a r y Specification MIL-A-9067.
2-31
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-~ ~ ____ __.___.__-
MIL-HDBK-23A CHG NOTICE 3 m 9999970 0147898 T3L m
(2-37) U . S . DEPARTMENT O F DEFENSE

Current Adhesive, Metallic S t r u c t u r a l Sandwich Construction.

Current C o r e Mate rial, Aluminum, f o r Sandwich Construction.
M i l i t a r y Specification MIL-C-7438.

Current C o r e M a t e r i a l , P l a s t i c Honeycomb, L a m i n a t e d G l a s s F a b r i c
B a s e , f o r A i r c r a f t S t r u c t u r a l Applications. M i l i t a r y Specifi-
cation M I L - c - 8 0 7 3 .

Current C o r e M a t e r i a l , F o a m e d - I n - P l a c e , Urethane Type. Military
Specification MIL-C-8087 o

Current C o r e M a t e r i a l s . M e t a l l i c . Heat-R e s i s t a n t . -
~~~~
for Structural
~~
Sandwich Construction. M i l i t a r y Specification MIL-C-21275.

Current L u m b e r , Hardwood, Mahogany, A i r c r a f t Quality. Military
Specification MIL-L-797 O .

Current Sandwich C o n s t r u c t i o n , C o r e M a t e rial, B a l s a Wood.
M i l i t a r y Specification MIL-S -7998.

C u r r e n t 'Sandwich C o n s t r u c t i o n , P l a s t i c R e s i n , G l a s s F a b r i c B a s e ,
L a m i n a t e d F a c i n g s and U r e t h a n e F o a m e d - I n - P l a c e C o r e ,
f o r S t r u c t u r a l Applications M i l i t a r y Specification MIL-S -25392.

Current Sandwich C o n s t r u c t i o n and C o r e M a t e r i a l s ; G e n e r a l T e s t
Methods. M i l i t a r y S t a n d a r d MIL-STD-401.
2-32
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

(2-46) U. S. FOREST PRODUCTS LABORATORY , FOREST SERVICE
1955. WoodHandbook. U.S. Dep. A g r . , Agr. Handb. 72.
(2-47) U. S. GENERAL SERVICES ADMINISTRATION

Current Adhesives , Heat R e s i s t a n t , Airframe S t r u c t u r a l , Metal-to-
Metal. F e d e r a l Specification MMM-A- 132. F e d e r a l Supply _ _
Services.
(2-48) VOSS, A . W . , andNORRIS, C. B.

1949. C r e e p T e s t s of Sandwich Constructions Subjected t o S h e a r at
N o r m a l T e m p e r a t u r e s . U.S. F o r e s t P r o d . Lab. Rep. 1806.
(2-49) WERREN, F.
1952. S h e a r - F a t i g u e P r o p e r t i e s of Various Sandwich Constructions.
(2-50) W I E P K I N G , C. A . , a n d D O Y L E , D. V.
1944. S t r e n g t h and Related P r o p e r t i e s of B a l s a and Quip0 Woods.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(2-51) WILKS, S. S.
1948. Sampling and Its Uncertainties. A m e r i c a n Society f o r T e s t i n g
M a t e r i a l s , P r o c e e d i n g s Vol. 48.
2 -33

MIL-HDBK-23A CHG NOTICE 3 9997970 0147900 4 1 T
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MIL-HDBK-23A CHG N O T I C E 3 W 9999970 0347924 9 5 3
Table 2-9.--Strength of Adhesives in Sandwich with Honeycomb Core-1
:Lb /in.:Lb /in.:Lb

-- /inm:Inv-lb:In,-lb :In.-lb
: lin. : -lin. : --
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Nitrile elastomer-phenolic
plus modified epoxy film : 73 : 51 : 84 : 66 : 32 : 21
Po lyvinyl-pheno1ic : 42 : 35 : 49 : 25 : 22 : 14
Epoxy-polyamide : 71 : 39 : 66 : 18 : 24 : 15
Modified epoxy
(350'F cure) : 62-86 : 27-65 : 61-87 : 16-97, : 13-82 : 12-49
Modified epoxy
(250F cure) : 46-76 : 34-38 : 47-91 : 15-40 : 18-23 : 19-26
Nitrile epoxide : 61 : 33 : 89 : 27 : 18 : 28
-Tests
1 described in ref. 2-37,
2
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Figure 2 - 2 . - - C e l l c o n f i g u r a t i o n s f o r formable honeycomb c o r e s .

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F i g u r e 2-9. --Effect of c o r e thickness on s h e a r s t r e n g t h .

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F i g u r e 2 - 1 2 . --Effect of c o r e m o i s t u r e content on s h e a r and c o m p r e s s i v e

stiffness of r e s i n - t r e a t e d p a p e r honeycomb c o r e .
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AVERAGE COMPRESS/VE s nwww LESS Two STANDARD DEVIATIONS /psi~
M 132 7 3 ~
F i g u r e 2 - 1 4 . --Graph of m i n i m u m c o m p r e s s i v e s t r e n g t h .
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M 132 734 STANDARD DEVIATIONS (psi)
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length t o a d h e r e n d thickness.

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-
MIL - HDBK- 2 3 A
CHAPTER 3 3 0 Dec 1968
WRINKLING O F SANDWICH FACINGS UNDER EDGEWISE LOAD
3 . 1 BASIC PRINCIPLES
Wrinkling of sandwich facings, as shown i n figure 1-1D of the Introduc-

tion, Chapter 1 , m a y occur i f a sandwich facing buckles a s a plate on an
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
e l a s t i c foundation. Analysis of this localized buckling behavior i s compli-

c a t e d by unknown waviness of sandwich facings. T h u s , the d e s i g n e r m u s t ,
i n effect, consider the buckling of a column (facing) that is supported on an
e l a s t i c foundation ( c o r e ) and that is not initially s t r a i g h t . The initial c u r v a -
t u r e o r deflection (waviness) is not e a s i l y defined o r e a s i l y m e a s u r e d , and
a t t e m p t s t o c o r r e l a t e wrinkling d a t a , including m e a s u r e d facing waviness,
with t h e o r y have not been v e r y s u c c e s s f u l . Growth of initial waves c a u s e s
s t r e s s e s i n the c o r e and i n the bond between facings and c o r e . F i n a l f a i l u r e
m a y o c c u r suddenly and the facing m a y buckle inward o r outward, depending
on the flatwise c o m p r e s s i v e s t r e n g t h of the c o r e r e l a t i v e to the flatwise
t e n s i l e s t r e n g t h of t h e bond between the facing and c o r e . Information given
h e r e should not be used a s a p r i m a r y m e a n s of sandwich design, but should
be used i n conjunction with information on g e n e r a l buckling, deflection, e t c .
The final design should be checked to a s c e r t a i n whether wrinkling of the
sandwich facings might o c c u r at design load. Because of u n c e r t a i n t i e s i n
a n a l y s i s and values of m a t e r i a l p r o p e r t i e s , i t is r e c o m m e n d e d that the f i n a l
d e s i g n be checked by t e s t s of a few s m a l l s p e c i m e n s ( s e e r e f s . 3 - 1 and 3 - 6
f o r test methods) a
The facings of a sandwich s h a l l not wrinkle under design load. The

information given h e r e a s s u m e s that t h e facing and c o r e p r o p e r t i e s and
d i m e n s i o n s a r e known. The p r o p e r t i e s s h a l l be values at the condition of
u s e ; t h a t i s , if application is at elevated t e m p e r a t u r e , then p r o p e r t i e s at
elevated t e m p e r a t u r e s h a l l be used i n design. The facing modulus of e l a s -
t i c i t y is the effective value at the facing s t r e s s . If this s t r e s s is beyond
the proportional l i m i t value, an a p p r o p r i a t e tangent, reduced, o r modified
c o m p r e s s i o n modulus of e l a s t i c i t y s h a l l be used ( r e f . 3-5).
The wrinkling s t r e s s f o r m u l a s a r e given for two types of sandwich;

sandwich with continuous c o r e s and sandwich with honeycomb c o r e s f o r
which e l a s t i c moduli i n the plane of the c o r e a r e v e r y s m a l l c o m p a r e d with
the e l a s t i c modulus i n a d i r e c t i o n n o r m a l t o the c o r e plane.
3- 1

-- -
I MIL-HDBK-23A CHG N O T I C E 3
-
9999970 0147949 223 =

~-
3 . 2 SANDWICH WITH CORE SUPPORTING
FACINGS CONTINUOUSLY
The s t r e s s at which wrinkling of sandwich facings on a continuous c o r e

w i l l o c c u r is given approximately by the f o r m u l a ( r e f . 3 - 2 ) :
(3: 1)
where F i s facing wrinkling s t r e s s ; E ' is effective facing e l a s t i c modulus

W
i n the d i r e c t i o n of the applied load; X is one minus the product of two
P o i s s o n ' s r a t i o s ; E is c o r e e l a s t i c modulus in a d i r e c t i o n n o r m a l to the
C
sandwich facings; G is c o r e s h e a r modulus a s s o c i a t e d with s h e a r d i s t o r t i o n
C
i n the plane perpendicular t o the facings and p a r a l l e l to the d i r e c t i o n of
applied load; and Q is the r e l a t i v e m i n i m u m with r e s p e c t to 5 of the
expr es si on
(3:2)
where
(3:3)
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6 E
(3:4)
and t is c o r e thickness; t is facing t h i c k n e s s ; 6 is initial deflection of

C
facing waviness; and F is flatwise sandwich s t r e n g t h (the l e s s e r of flatwise
C
c o r e c o m p r e s s i o n o r sandwich flatwise tension). The p a r a m e t e r 5 is p r o -
portional to the fourth root of the r a t i o of the c o r e e l a s t i c
moduli and t o t h e r a t i o of the c o r e thickness to the ideal buckle wavelength
(see ref. 3 - 2 f o r details).
3-2

.- - ________-
MIL-HDBK-23A CH6 N O T I C E 3 9999970 0 3 4 7 9 5 0 T 4 5
A graphical presentation of Q ( m i n i m u m values of f o r m u l a 3:2) is given

in f i g u r e 3-1. T h e g r a p h can be e n t e r e d at known values of the a b s c i s s a , q ,
and t h e o r d i n a t e , Q, d e t e r m i n e d a f t e r choosing a n e s t i m a t e d K c u r v e . P r e s -
ent s t a t e of the a r t d o e s not p e r m i t a s u i t a b l e choice f o r values of 6 . If t e s t
values of wrinkling s t r e s s e s a r e known, t h e g r a p h of f i g u r e 3 - 1 c a n be used
t o . d e t e r m i n e which K c u r v e f i t s t h e d a t a and then compute values of 6 f r o m
f o r m u l a (3:4). Changes i n design f o r similar sandwich c a n then be m a d e by
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a s s u m i n g 6 t o be a constant f o r t h a t p a r t i c u l a r type of sandwich and then

using the graph of f i g u r e 3-1 t o r e d e s i g n .
Examples :
1. A sandwich h a s O . 067-inch facings on a l - i n c h c o r e . C o r e e l a s t i c

p r o p e r t i e s a r e E = 5 0 , 0 0 0 pounds p e r s q u a r e inch and G = 20,000 pounds
C C
per s q u a r e i n c h . Facing e l a s t i c modulus is ( E l i ) = 10, 0 0 0 , 0 0 0 pounds p e r
s q u a r e inch at a design s t r e s s of 43,000 pounds p e r s q u a r e i n c h . D e t e r m i n e
whethersandwich facings w i l l wrinkle under t h i s d e s i g n s t r e s s . Values of
Q and q w e r e computed f r o m f o r m u l a s (3: 1) and (3:3) t o be O. 20 and 1. 39,
r e s p e c t i v e l y . T h e g r a p h of f i g u r e 3-1 shows t h e value of K t o be about 1. 2
and f r o m the definition of K ( f o r m u l a 3:4) , 6 w a s computed t o be O . O 12 inch
o r F = 500 pounds p e r s q u a r e inch. T h i s s e v e r e a n amplitude of waviness
C
f o r a O. 067-inch facing s e e m s unlikely, hence wrinkling at d e s i g n s t r e s s
would be unlikely even though t h e f o r m u l a i s not exact.
2. Solution of f o r m u l a (3: 1) f r o m t e s t values r e s u l t s in Q = O. 32 and

solution of f o r m u l a (3:3) give q = 3.86. T h e g r a p h of f i g u r e 3-1 shows t h a t
t h e c u r v e K = O . 20 p a s s e s through t h e point designated by t h e s e values of Q
and q. In o r d e r t o i n c r e a s e t h e value of t h e wrinkling s t r e s s by 50 p e r c e n t ,
t h e value of Q m u s t i n c r e a s e f r o m 0 . 3 2 to 0 . 4 8 , and then t h e value of K
m u s t d e c r e a s e t o about O. 092 f o r the s a m e value of q . T h u s , the c o r e o r
sandwich f l a t w i s e s t r e n g t h , F , would have t o be i n c r e a s e d by a f a c t o r of
C
about O. 20/0.09 = 2. 2 t o raise t h e wrinkling s t r e s s by 50 percent. Another
way t o obtain a n i n c r e a s e i n wrinkling s t r e s s is t o i n c r e a s e the facing thick-
n e s s , t , without changing c o r e o r sandwich f l a t w i s e s t r e n g t h . This r e s u l t s
i n s l i d i n g up the K = O. 20 c u r v e until Q = O. 48 at which point q = 1. 7 5 and
thus t i n c r e a s e s by a f a c t o r of 3.86/1. 75 = 2. 2. T h i s would be a bit c o n s e r v -
ative b e c a u s e it is a s s u m i n g 6 is t h e same f o r facings of d i f f e r e n t t h i c k n e s s .
F r o m f o r m u l a ( 3 : 1) it is a l s o obvious t h a t a n i n c r e a s e i n e l a s t i c p r o p e r t i e s
w i l l a l s o i n c r e a s e wrinkling s t r e s s provided Q is not d e c r e a s e d too m u c h
by a n i n c r e a s e i n q .
3-3

_-___ ____ ~ _ _
MIL-HBEK-23A CHG N O T I C E 3 E 9999970 0147951 981 E
On the left side of f i g u r e 3-1, t h e c u r v e s t e r m i n a t e i n a s t r a i g h t l i n e

represented by Q = 1/2q. Substitution of t h i s into (3: 1) and r e p l a c i n g q by
(3:3) r e s u l t s in t h e f o r m u l a
t C
F =- c c ( 3 :5)
w 2t
which is the same r e s u l t as obtained f o r t h e " s h e a r c r i m p i n g " mode defined

by a limit of t h e g e n e r a l buckling m o d e s and i l l u s t r a t e d i n f i g u r e 1-1B of t h e
Introduction, C h a p t e r 1 .
F i g u r e 3-2 p r e s e n t s a g r a p h i c a l m e a n s f o r d e t e r m i n i n g K v a l u e s f r o m
t h e r a t i o s 6 / t and F / E
C c c
.
T h e g r a p h is a l s o useful i n d e t e r m i n i n g 6 / t
C
v a l u e s f r o m known v a l u e s of F / E and K.
c c
3 . 3 SANDWICH WITH HONEYCOMB CORES
Solution of t h e g e n e r a l e x p r e s s i o n s f o r wrinkling of sandwich facings on

honeycomb c o r e s leads to s o m e w h a t d i f f e r e n t r e s u l t s b e c a u s e f o r honeycomb
c o r e s t h e e l a s t i c moduli i n t h e plane of t h e c o r e (EL, Ew are very sL)
s m a l l c o m p a r e d with e l a s t i c moduli i n a d i r e c t i o n n o r m a l t o t h e c o r e plane
( E T , G T L , GT$. T h e s t r e s s a t which wrinkling of sandwich facings on a
honeycomb c o r e w i l l o c c u r i s given a p p r o x i m a t e l y by the f o r m u l a (ref. 3 - 3 )
E t '1/2
O. 8 2 (&- E'
C I
F = (3:6)
W 1 t 0.64K
w h e r e t h e s y m b o l s have t h e same m e a n i n g as given previously. A nondimen-

s i o n a l graph of f o r m u l a (3:6) is given i n f i g u r e 3-3. Solution of t h e f o r m u l a
is c a r r i e d out t h e same as f o r the sandwich with continuous c o r e s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
T h e wrinkling of sandwich facings b r a z e d to honeycomb c o r e s h a s been

i n v e sti gat ed e x p e r i m e n t ally and analyzed s t a t i s t i c ally for h a r d e n e d alloy s
of 17-7PH and PH15-7Mo steel ( r e f . 3-4). T h e r e s u l t a n t statistical f o r m u l a
f o r wrinkling s t r e s s w a s given a6
F '
' F
= 2 6 6 , 8 2 0 l o g l o \ , o ocyo
'
\ t 6 8 , 5 7 8 log 10p c t 17, 175 l o g l o
W
\ i (3: 7)
15) - 4 5 4 , 9 7 8
3-4

- - __
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0347952 L m
where F is wrinkling s t r e s s of t h e facing i n pounds p e r s q u a r e inch; F

W CY
is c o m p r e s s i v e yield s t r e s s of the facing in pounds per s q u a r e inch; p is
C
c o r e d e n s i t y i n pound6 p e r cubic foot; t is c o r e thickness; t is facing t h i c k -
C
n e s s ; and 6 is c o r e cell s i z e . D i r e c t u s e of f o r m u l a (3:7) f o r m a t e r i a l s
o t h e r t h a n t h o s e f o r which i t w a s obtained is not r e c o m m e n d e d without t e s t
verification.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(3-1) AMERICAN SOCIETY FOR TESTING AND MATERIALS

Edgewise C o m p r e s s i v e Strength of F l a t Sandwich C o n s t r u c -
t i o n s . ASTM Method C364.
(3-2) NORRIS, CHARLES B . , ERICKSEN, WILHELM S . , MARCH, H. W . ,

AND OTHERS
1949. Wrinkling of t h e F a c i n g s of Sandwich Constructions Subjected
t o Edgewise C o m p r e s s i o n . U . S . F o r e s t P r o d . Lab. Rep.
1810.
(3-3) NORRIS, CHARLES B . , BOLLER, KENNETH H . , AND

VOSS, ARNOLD W .
1953. Wrinkling of the Facings of Sandwich Construction Subjected
t o Edgewise C o m m e s s i o n - -Sandwich Constructions Having
Honeycomb C o r e s . U.S. F o r e s t P r o d , Lab. Rep. 1810A.
(3-4) NORTH AMERICAN AVIATION, INCORPORATED

1963. A S t a t i s t i c a l Analysis of the Wrinkling Strength of B r a z e d
Honeycomb Sandwich S t r u c t u r e and a C o m p a r i s o n with Theory.
Rep. NA-62-1279.
(3-5) U. S . D E P A R M E N T O F D E F E N S E
Current Metallic M a t e r i a l s and E l e m e n t s f o r A e r o s p a c e Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U. S .
Cov. P r i n t i n g Office, Washington, D. C.
(3-6) U. S . DEPARTMENT O F DEFENSE

Current Sndwich Constructions and C o r e M a t e r i a l s ; G e n e r a l T e s t
Methods. Military Standard MIL-STD-40 1.
3 -5

_ _ ~ - _ _ -~
NIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 7 9 5 3 7 5 4 U
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MIL-HDBK-23A CHG N O T I C E 3 W 9979970 0347754 670 m
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-- Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard
-
MIL -HDBK 2 3 A
19 June 1974
CHAPTER 4 -- DIMPLING OF SANDWICH

FACINGS UNDER EDGEWISE LOAD
Page
4.1 Ba s i c P r i n c i p l e s 4 -1
4.2 Sandwich Having C e l l u l a r (Honeycomb) Core 4-1
4.3 Sandwich Having C o r r u g a t e d Core 4 -2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

.- ___ -
MIL-HDBK-23A Cut5 N O T I C E 3 W 7799770 8347757 3 T T
MIL-HDBK- 2 3 A
19 June 1974
CHAPTER 4
DIMPLING OF SANDWICH FACINGS UNDER EDGEWISE LOAD
4.1 BASIC PRINCIPLES
If t h e core of a sandwich construction i s of c e l l u l a r (honeycomb) o r

corrugated m a t e r i a l , it i s p o s s i b l e f o r t h e facings t o buckle o r dimple i n t o
t h e spaces between core walls o r corrugations. Dimpling o f t h e facings may
n o t lead t o f a i l u r e unless t h e amplitude of t h e dimples becomes l a r g e and
- causes t h e dimples o r buckles t o grow across core c e l l walls and r e s u l t i n
wrinkling of t h e facings. Dimpling t h a t does not cause t o t a l s t r u c t u r a l f a i l u r e
may, of course, be severe enough s o t h a t permanent dimples remain a f t e r removal
of load.
If dimpling o f t h e facings i s not permissible, t h e core c e l l s i z e o r corru-

g a t i o n spacing s h a l l be small enough s o t h a t dimpling w i l l not occur under
design loads. I t i s assumed t h a t f a i l u r e i n t h e facing-to-core bond cannot
occur p r i o r t o dimpling. The design procedures a l s o assume t h a t a facing
thickness ( t ) i s known (facing thickness having been determined by consider-
a t i o n of design loads and chosen design compressive facing s t r e s s e s ) ; t h a t
facing compressive s t r e s s Fc and e f f e c t i v e compressive modulus of e l a s t i c i t y
E ' a r e known; and t h a t t h e core c e l l s i z e o r corrugation spacing i s t o be
determined. The facing p r o p e r t i e s s h a l l be values a t t h e condition o f use;
t h a t i s , i f a p p l i c a t i o n i s a t elevated temperature, then facing p r o p e r t i e s a t
elevated temperature s h a l l be used i n design. The facing modulus of e l a s -
t i c i t y i s t h e e f f e c t i v e value a t t h e facing s t r e s s . I f t h i s s t r e s s i s beyond
t h e proportional l i m i t value, an appropriate tangent, reduced, o r modified
compression modulus of e l a s t i c i t y s h a l l be used ( r e f . 4 - 4 ) .
Because of u n c e r t a i n t i e s i n a n a l y s i s and values of m a t e r i a l p r o p e r t i e s ,

it i s recommended t h a t t h e f i n a l design be checked by t e s t s of a few small
. specimens (see r e f s . 4-1 and 4-5 f o r t e s t methods).
4.2 SANDWICH HAVING CELLULAR (HONEYCOMB) CORE
This s e c t i o n gives t h e procedure f o r determining t h e core c e l l s i z e such

t h a t an i s o t r o p i c sandwich facing w i l l not dimple ( r e f . 4-3).
Supersedes Chapter 4 of 30 December 1968.
4- 1
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- - - -
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 OLV7958 236
MIL-HDBK-23A
19 June 1974
The facing stress at which dimpling of the sandwich facing will occur is
given by the empirical formula
(4:1)
where E ' is effective compressive modulus of elasticity of the facing at stress

Fc, A = 1 - p2 when p is Poisson's ratio of facings, t is facing thickness and
s is core cell size (diameter of inscribed circle).
Solving formula (4:l) for s results in
s = t6&-)-; (4:2)
Determine maximum core cell size from formula (4:2) o r by graphical

solution using the chart in figure 4-1. If the core cell size is smaller than
available, it is necessary to use a thicker facing and a lower stress in order
that dimpling will occur at the same edge.load. The chart of figure 4-1 can
also be used to find facing thicknesses and stresses for dimpling of sandwich
facings on cores of a particular cell size.
4.3 SANDWICH HAVING CORRUGATED CORE
This section gives the procedure for determining the spacing between
core corrugations such that sandwich facing o r core elements will not buckle
(refs. 4-2, 4-7, and 4 - 8 ) . For edge compression load in a direction parallel
to the core axis, the design procedure is based on the buckling load of the un-
supported facing o r core element, whichever is the lower, although it may be
possible to utilize a sandwich in which the core elements are buckled. For
edge compression load in a direction perpendicular to the core axis, the
design procedure is based on the buckling load of the unsupported facing ele-
ment and the core is assumed to be rigid enough to cause rotational restraint
at the ends of the facing element. If the core is double corrugated, it may
not have sufficient flatwise strength to cause-the facing elements to buckle
as assumed.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
The facing stress at which buckling of the facing element or core element
will occur is given by the formula
(4:3)
4-2

-___ ___
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0347959 372
___-
=
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
MI L-HDBK- 23A
19 June 1974
where E ' i s t h e e f f e c t i v e compressive modulus of e l a s t i c i t y of t h e f a c i n g a t

stress Fc; h = 1 - '2, u being Poisson's r a t i o of t h e facing; t i s facing thick-
ness; b i s unsupported width o f facing element; and k i s a c o e f f i c i e n t dependent
upon t h e r a t i o ( t o / t ) o f t h e corrugation thickness (to) t o t h e facing thickness
( t ) , t h a angle (0) between t h e corrugation element and t h e facing, and t h e type
of material, i . e . , i s o t r o p i c o r o r t h o t r o p i c .
Solving formula (4:3) f o r b r e s u l t s i n
b = t k <(F.)- - (4:4)
Graphical s o l u t i o n s f o r formula (4:4) are given i n c h a r t s of f i g u r e s 4-2

t o 4-12. A l l c h a r t s except t h a t of f i g u r e 4-12 apply t o sandwich i n which t h e
load i s i n a d i r e c t i o n p a r a l l e l t o t h e core a x i s . The c h a r t of f i g u r e 4-12
a p p l i e s t o sandwich with t h e load i n a d i r e c t i o n perpendicular t o t h e core a x i s .
Charts of f i g u r e s 4-2 and 4-3 apply t o sandwich with facings and core of t h e
same i s o t r o p i c material. Charts o f f i g u r e s 4-4 t o 4-11 apply t o sandwich of
o r t h o t r o p i c materials such as g l a s s f a b r i c laminates* f o r which a = 2 / 3 , 1,
o r 3/2, and = 0.6 as i n d i c a t e d on t h e c h a r t s . The values o f a anddepend
upon t h e e l a s t i c p r o p e r t i e s as follows:
where E ' and E' are t h e moduli o f e l a s t i c i t y p a r a l l e l and perpendicular t o t h e

a b
d i r e c t i o n of loading, G i a i s t h e shear modulus associated with those d i r e c t i o n s ,
i s t h e Poisson's r a t i o of t h e c o n t r a c t i o n i n t h e b d i r e c t i o n t o extension i n
- 'ab
t h e a d i r e c t i o n due t o a t e n s i l e stress i n t h e a d i r e c t i o n . pba i s s i m i l a r l y
defined, and h =
'- ' b' b a
a
Symbols subscripted with o such a s a o , Bo, e t c .
i n d i c a t e d p r o p e r t i e s of t h e core material.
*Laminates giving t h e following values of a and were of g l a s s f a b r i c s 1 1 2 ,

116, 120, 128, 143, 162, 164, 181, 183, and 184 ( r e f . 4-6)
4- 3

___-I-
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0347960 9 9 4 m
MIL-HDBK-23A
19 June 1974
After choosing 0 and determining b from t h e c h a r t s , t h e geometry of t h e

sandwich cross s e c t i o n i s now fixed so t h a t t h e d i s t a n c e , h, between t h e
facing centroids i s given by
h = (b/2) t a n 0 ( s i n g l e corrugated core) (4:s)

h = b t a n 6 (double corrugated core) (4:6)
Since t h e dimension h may be determined previously by sandwich

s t i f f n e s s or s t r e n g t h requirements, i t w i l l be necessary t o determine b by
solving formula (4:s) o r (4:6). Graphical s o l u t i o n s f o r determining b from
formula (4:s) o r (4:6) are given i n t h e lower p o r t i o n of t h e c h a r t s o f f i g u r e s
4-2 t o 4-12. The f i n a l design w i l l be based on t h e value of b determined by
s o l u t i o n of formula (4:s) o r (4:6) and b s h a l l be no g r e a t e r than t h e s o l u t i o n
of formula (4:4). By i t e r a t i o n , it i s p o s s i b l e t o choose 6 s o t h a t values of b
determined by c h a r t s f o r formula (4:4) are t h e same as determined by t h e c h a r t s
f o r formula (4:s) o r (4: 6 ) .
4- 4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~- - -~
__. ~ -~
MIL-HDBK-23A CHG N O T I C E 3 m 9777770 O347763 AZO m
MI L-HDBK-23A
19 June 1974

Edgwise Compressive Strength of Flat Sandwich Constructions.
ASTM Method C364.
(4-2) ANDERSON, MELVIN S .

1959.. Local Instability of the Elements of a Truss-Core Sandwich
Plate. NASA Tech. Rep. TR R-30.
(4-3) NORRIS, C.B.

1964. Short-Column Compressive Strength of Sandwich Constructions
as Affected by Size of Cells of Honeycomb Core Materials.
U.S. Forest Serv. Research Note FPL-026. Forest Prod. Lab.,
Madison, Wis.
(4-4) U.S. DEPARTMENT OF DEFENSE

Current Metallic Materials and Elements for Aerospace Vehicle Structures.
Military Handbook 5. Available from U.S. Gov. Printing Office,
Washington, D.C.

Current Sandwich Constructions and Core Materials; General Test
Methods. Military Standard MIL-STD-401.

Current Plastics for Flight Vehicles: Part I, Reinforced Plastics.
Military Handbook 17. Armed Forces Supply Support Center.
Available from U.S. Gov. Print. Office, Washington, D.C.
(4-7) WITTRICK, W. H.
1972. On the Local Buckling of Truss-Type Corrugated-Core
Sandwich Panels in Compression. Int. J . Mech. Sci.
Vol. 14, NO. 4, pp. 263-271.
(4-8) ZAHN, JOHN J .

1973. Local Buckling of Orthotropic Truss-Core Sandwich.
USDA Forest Serv. Res. Pap. FPL 220. Forest Prod.
Lab., Madison, Wis.
4-5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-~ - ~-
MIL-HDEK-23A C H G N O T I C E 3 M 9 9 9 9 9 7 0 O347962 767
MIL-HDBK-23A
19 June 1974
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I* 124 12s
Figure 4- 1 . --Chart for determining cellular core c e l l eize euch that dimpling
(intracel1 buckling) of isotropic sandwich facing will not occur.
4- 6
- -- -- ---
I -
Provided by IHS
No reproduction or networking permitted without license from IHS
Not for Resale, 09/27/2006 07:13:23 MDT
-- --_
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0147963 bT3 m
MIL-HDBK- 23A
19 .June 1974
o.IC
LEGEND:
-
---
FACING ELEMENT BUCKLES
CORE EL ENT BUCKLES
45'
50'
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
55'
e 60
65
70
I
A fINCffES/ 1
n 122 329
Figure 4 - 2 . --Chart for determining width, b, of facing element for isotropic

c o r r q a t e d - c o r e sandwich under compression edge load in a direction
parallel to c o r e axis (single corrugated core).

MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0347964 53T m
MIL-HDBK-~~A
MIL-HDBK-23A
19 June 1974
I IINCHJ
Figure 4- 3. --Chart for determining width, b, of facing element for isotropic

corrugated-core sandwich under compression edge load i n a direction
parallel to core axis (double corrugated core).
4-8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
----- .
- ----.
h.
~-
MIL-HDBK-23A
i9 J u n e 1974
f IINCHJ .
Figure 4-4. --Chart for determining width, b, of facing element for
orthotropic corrugated-core sandwich under compression edge load in a

direction parallel to c o r e axis (single corrugated c o r e ) . M 141 6 3 7
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~- - ~ ~
MIL-HDBK-23A CHG N O T I C E 3 9999970 O347966 302 m
I /INCHI
MIL-HDBK- 23A
19 June 1974
o. IO
LEGEND :
- FACING ELEMENT BUCKLE.
--- CORE. ELEMENT JUCKLES
O
'
I
h IINCHESJ
ata, = i
,&=Bo
= 0.6
O.5
I. 5
2.O
Figure 4-5. --Chart for determining width, b, of facing elemtnt for

orthotropic corrugated-core sandwich under compression edge load tn a
direction parallel to core axis (single corrugated c o r e ) . M 141 638
4-10
- . _-- ---- - - -- --
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__ -. _ _-- --
MiL-HBBK-23A CHG N O T I C E 3 m 7 9 9 7 9 7 0 0147967 2 4 9 m
MIL-HDBK-23A
19 June 1974
t (INCHI
8d w
o
*o 8 d 8
0 o 0:
d
o.io
LMEN:
- FA G ELEMENT eucmrs
--- CORE ELEMENT e u c a m
45.
50'
e 25:
65'
70'
O I 2 3
O
atao=j
=p0= 0.6 O.5
i. i
2.o
Figars 4-6. --Chart for determining width, b, of facing element for

ortbot.ropic corrugated-core sandwich under compreeeion edge load in a
direction perallel to core axis (8ingle.corrugated core). M 141 639
--
- ___- -_
~
4-11
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

V
MIL- HDBK- 2 3A o
19 June 1974
o. IO
L EtEN .-
-
---
FACING E i EA'EUT BUCUL ES
CORE EL EMCN i BUCUL ES
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
45.
50
e' g:'
65.
70.
CY= J'
ao= 3
,&=Bo=
0.6
-
0 A O
A
Eo0
= 2.25
-
A Fc
E
Figure 4 - 7 . --Char for determining width, b, of facing element for

orthotropic corrugated-core sandwich under compression edge load i n a
direction parallel to core axis (single corrugated a x i s ) . M 141 640
4-12

___. -
flIL-HDBK-23A CHG N O T I C E 3 M 9999970 0347969 O L L M
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
MIL-HDBK-23A
19 June 1974
I IfffCff/ . n
<o O
Q O
ci ci
LEGEND .-
- FACING ELEMENT BL'CKLES
.I
Figure 4 - 8 . --Chart for determning width, b, of facing element for

direction parallel to c o r e axis (single corrugated c o r e ) . M 141 641
--- 4-13

MIL-HDBK-23A C H G N O T I C E 3 m 9 9 9 9 9 7 0 0347970 833 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
MIL-HDBK-23A
19 June 1974
Figure 4 - 9 . --Chart for determining width, b, of facing element for

direction parallel to core axis (single corrugated core 1. M 141 642

-~ __
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0 1 4 7 9 7 1 77T m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Figure 4- 10. --Chart for determining width, b, of facing element for

orthotropic corrugated- core sandwich wider compreeeion edge load in a
direction parallel to core axis (single corrugated core). M 141 643
---__ - 4- 15
-. _.

I ~~
MIL-HDBK-23A CHG N O T I C E 3 = 9 9 9 9 9 7 0 0347972 606
32
I
h /INCHES)
a =I
ao=$
/=Po=
0.6
-
Eo .Io
00 A
= 1.5
Figure 4- 11. - - C h a r t for clctermiiiing width, b, of facing element for

orthotropic corrugated-core sandwich under' compression edge load in a
direction parallel to c o r e axis (single corrugated c o r e ) . M 141 644
4- 16
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-~~
-
=
I
MIL-HDBK-23A CHG N O T I C E 3 9999970 0347973 5 4 2
MI L- HDBK- 23A
19 June 1974
t (mcn)
v,
?
o'
Q
O co
o
o'
o
O
d
0
CL O B
0'0:
LEGEM :
- SINGLE CORRUGAT CORE
--- DOUBLE CORRUGAkED CORE
O 0.5 I. o 1.5 2.0 2.5

d
'I h (INCHES)
Figure 4- 12. --Chart for determining width, b, of facing element for

corrugated-core sandwich under compreseion edge load in a direction
perpendicular to c o r e axis. M 141 645
4-17
-- -- -- -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_ _
M I L - H D B K - 23A
3 0 D e c 1568
CHAPTER 5
DESIGN O F F L A T RECTANGULAR SANDWICH P A N E L S
UNDER EDGEWISE COMPRESSION LOAD

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
5 . 1 BASIC P R I N C I P L E S
A s s u m i n g t h a t a d e s i g n begins with c h o s e n d e s i g n s t r e s s e s and a gi\-en

l o a d t o t r a n s m i t , a f l a t r e c t a n g u l a r p a n e l of s a n d w i c h c o n s t r u c t i o n u n d e r
e d g e w i s e c o m p r e s s i o n l o a d s h a l l be d e s i g n e d t o c o m p l y w#ith t h e f o u r b a s i c
d e s i g n p r i n c i p l e s s u m m a r i z e d i n 1 . 2 of I n t r o d u c t i o n . T h e s e i o u r c o n d i t i u n s
m u s t b e met.
O v e r a l l b u c k l i n g of t h e s a n d w i c h o r d i m p l i n g o r w r i n k l i n g of t h e f a c i n g s
c a n n o t o c c u r w i t h o u t p o s s i b l e t o t a l c o l l a p s e of t h e p a n e l . D e t a i l e d p r o c e -
d u r e s g i v i n g t h e o r e t i c a l f o r m u l a s a n d g r a p h s f o r d e t e r m i n i n g d i m e n s i u n s of
t h e f a c i n g s a n d c o r e , as w e l l as n e c e s s a r y c o r e p r o p e r t i e s . a r e g i v e n i n
following p a r a g r a p h s . Double f o r m u l a s a r e given. one f o r m u l a f u r sandwich
w i t h f a c i n g s of d i f f e r e n t m a t e r i a l s a n d t h i c k n e s s e s a n d a n o t h e r f o r m u l a f o r
s a n d w i c h w i t h e a c h f a c i n g of t h e s a m e m a t e r i a l a n d t h i c k n e s s . F a c i n g i n o d -
u l u s of e l a s t i c i t y , E ' a n d s t r e s s v a l u e s , F c , s h a l l b e c o m p r e s s i o n \ - a l u e s
~
a t t h e c o n d i t i o n s of u s e ; t h a t i s , i f a p p l i c a t i o n is a t e l e v a t e d t e m p e r a t u r e .
t h e n f a c i n g p r o p e r t i e s a t e l e v a t e d t e m p e r a t u r e s h a l l be u s e d i n d e s i g n . T h e
f a c i n g m o d u l u s of e l a s t i c i t y is t h e e f f e c t i v e v a l u e a t t h e f a c i n g s t r e s s . If
t h i s s t r e s s is b e y o n d t h e p r o p o r t i o n a l l i m i t v a l u e , a n a p p r o p r i a t e t a n g e n t ,
r e d u c e d , o r m o d i f i e d c o m p r e s s i o n m o d u l u s of e l a s t i c i t y s h a l l b e u s e d ( r e f .
ref. 5-5).
5 . 2 DETERMINING FACING THICKNESS
F a c i n g s t r e s s e s a r e r e l a t e d t o t h e e d g e l o a d by t h e e q u a t i o n s :
t F
1 cl
+ t 2 Fc 2 =N (for unequal facings) (5: 1)
N
t = - (for equal facings) (5: i a )
ZF
C
w h e r e t is f a c i n g t h i c k n e s s ; F is c h o s e n d e s i g n f a c i n g c o m p r e s s i v e s t r e s s ;
C
N is d e s i g n c o m p r e s s i o n l o a d p e r u n i t l e n g t h of p a n e l e d g e ; a n d 1 , 2 a r e
s u b s c r i p t s denoting f a c i n g s 1 a n d 2.
5-1

MIL-HDBK-23A CHG N O T I C E 3 9997970 0347975 335 U
In d e t e r m i n i n g t h i c k n e s s e s of facings f o r sandwich with facings of d i f f e r e n t

m a t e r i a l s , equation (5: 1) m u s t be s a t i s f i e d , but a l s o t h e s t r e s s e s F and
cl
Fc2 m u s t be chosen s o t h a t F / E
cl sl
= F c 2 / E s 2 ( w h e r e E S is facing s e c a n t
modulus of e l a s t i c i t y ) , thus avoiding o v e r s t r e s s i n g of e i t h e r facing. F o r
e x a m p l e , if facing 1 is o a m a t e r i a l s u c h that the r a t i o F / E = O . 005 and
cl sl
facing 2 i s o f a m a t e r i a l s u c h t h a t t h e r a t i o F / E = O . 002, t h e design m u s t
c2 s 2
be b a s e d on a r a t i o of 0 . 0 0 2 , o t h e r w i s e facing 2 w i l l be o v e r s t r e s s e d . In
o r d e r t o a c c o m p l i s h t h i s , t h e chosen d e s i g n s t r e s s f o r facing 1 m u s t be
lowered. F o r m a n y combinations of facing materials it w i l l be found advan-
tageous t o choose t h i c k n e s s e s s u c h t h a t E t = E2t2. If the c o r e c a n support
1 1
edge l o a d , 4 should be r e p l a c e d by t h e quantity ( N - F t ).
c c
5 . 3 DETERMINING CORE THICKNESS
AND CORE SHEAR IMODULUS
T h i s s e c t i o n gives p r o c e d u r e s f o r d e t e r m i n i n g c o r e thickness and c o r e

s h e a r modulus s o that o v e r a l l buckling of the sandwich panel w i l l not o c c u r
(refs. 5 - 1 , 5-2, and 5-3). T h e load p e r unit panel width at which buckling
of a sandwich panel w i l l o c c u r is given by t h e t h e o r e t i c a l formula:
2
IT
N =K- D
cr
b2
w h e r e D is sandwich bending s t i f f n e s s . T h i s f o r m ila, solved for the facing

s t r e s s , becomes:
2
E it E>t
=IT K (5:2)
Fel, 2 82
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
E i t l -t E ' t
2 21
2 .2
F =-
c
IT
4
jb/
K ' h ' E'
-
x (for equal facings) (5:2a)
5-2

MIL-HDBK-23A CHG NOTICE 3 9 9 9 9 9 7 0 0347976 251 M
w h e r e E' is e f f e c t i v e c o m p r e s s i v e m o d u l u s of e l a s t i c i t y of f a c i n g a t s t r e s s
7 2
F ( f o r o r t h o t r o p i c f a c i n g s E ' =\:E' E ' ) ; A = 1 - p. ; p. is P o i s s o n ' s r a t i o
C a b
of f a c i n g s ( i n i o r m u l a ( 5 : 2 ) i t is a s s u m e d t h a t p. = p l = p 2 ) ; h is d i s t a n c e
b e t w e e n f a c i n g c e n t r o i d s ; b is l e n g t h o f l o a d e d p a n e l e d g e ; K = K K .
M' F
K' is a t h e o r e t i c a l c o e f f i c i e n t d e p e n d e n t on f a c i n g s t i f f n e s s a n d p a n e l a s p e c t
F
r a t i o ; and K
is a t h e o r e t i c a l c o e f f i c i e n t d e p e n d e n t o n s a n d w i c h bei:ding and
M
shear rigidities and panel aspect ratio.
S o l v i n g e q u a t i o n s (5:2) a n d (5:Za) f o r h / b g i l - e s :
1 IAFcl,2 ,
E't
1 1
+ E>t2
-11= - (5:3)
- -
\ /-\
r
TI *-\I E;,2 E '1t -, E 2' t 2 , '
- i
!A F
--&--Y E'
11 C
- (for equal facings) (5: 3 a )
GlK
T h e r e f o r e , i f K is k n o w n , e q u a t i o n (5:3) o r ( 5 : 3 a ) c a n b e s o l v e d d i r e c t l y t o
eveiitually- o b t a i n 11 b e c a u s e . all o t h e r q u a n t i t i e s a r e known. A f t e r h i s
o b t a i n e d . t h e c o r e t h i c k n e s s , t , is c o m p u t e d f r o m t h e f o r m u l a s
C
t t t
1 2 (5: 4)
t = h -
C 2
t = h - t (for equal facings) (5:4a)

C
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
A s a f i r s t a p p r o x i m a t i o n , i t w i l l be a s s u m e d t h a t K = O, hence K = K
F M'
V a l u e s of K d e p e n d upoii t h e b e n d i n g a n d s h e a r r i g i d i t i e s of t h e s a n d w i c h
M
as i i i c o r . p o r a t e d i n t h e p a r a m e t e r
2
v = -T I D
b2U
w h i c h c a n b e w r i t t e n a6:
5-3
_ -
~ _ -
__ ~
~ ~~

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 3 4 7 9 7 7 L9B
2
t E't E't
IT
c 1 1 2 2
V= (5:5)
2 '
Ab G ! E f t t E ' t
c\ 1 1
2
IT t E't
C
V = (for equal facings) (5:5a)
2
2Xb G
C
I w h e r e U is sandwich s h e a r s t i f f n e s s ; G
C
is the c o r e s h e a r knodulus a s s o c i -
a t e d with the a x e s p a r a l l e l to d i r e c t i o n of loading ( a l s o p a r a l l e l to panel side
of length a) and perpendicular to the plane of the panel. A s values of c o r e
s h e a r modulus d e c r e a s e , v a l u e s of V i n c r e a s e and values of K gradually
M
d e c r e a s e . F o r sandwich with c o r r u g a t e d c o r e having c o r r u g a t i o n flutes
p a r a l l e l to d i r e c t i o n of loading t h e p a r a m e t e r V is r e p l a c e d by the p a r a m e t e r
(5:6)
2
IT t -E ' t
w= 2
L
( f o r equal facings) (5:6a)
2Xb G c b
I where G
cb
is the c o r e s h e a r modulus a s s o c i a t e d with the axes perpendicular
t o d i r e c t i o n of loading ( p a r a l l e l to panel s i d e of length b) and perpendicular
to the plane of the panel.
5 . 3 . 1 Determination of Minimum Values of h
A m i n i m u m value of h r e q u i r e d w i l l be d e t e r m i n e d by a s s u m i n g V = O
o r W = O for a first approximation. The value of h is m i n i m u m b e c a u s e
V = O o r W = O only i f t h e c o r e s h e a r modulus is infinite; for any actual
c o r e the s h e a r modulus is not infinite, hence a t h i c k e r c o r e m u s t be used.
T h e c h a r t of figure 5-1 gives m i n i m u m values of h for sandwich panels with
i s o t r o p i c o r orthotropic facings and c o r e and f o r v a r i o u s edge conditions.
P a n e l s with clamped edges are included i n the c h a r t of f i g u r e 5-1, although
t r u l y clamped edges a r e not actually attainable.
5-4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~~ -
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 7 7 0 0147978 0 2 4 m
T h e c h a r t s of f i g u r e s 5-1 t o 5-22 a r e applicable to sandlvich lvith

i s o t r o p i c facings f o r which CY = 1. O ; = 1. O ; y = O . 375 and t o sandLvich lvith
3 = O. 6;
o r t h o t r o p i c facings s u c h as g l a s s f a b r i c laminates:> f o r which Q = 1. O ; 1
y = 0.2.
T h e constants (Y, , and y depend upon e l a s t i c p r o p e r t i e s of the facings
as follows:
w h e r e E ' and E ' a r e the moduli of e l a s t i c i t y p a r a l l e l and perpendicular t o

a b
t h e d i r e c t i o n of loading, G ' is t h e facing s h e a r modulus a s s o c i a t e d w i t h
ba
those directions, is the P o i s s o n ' s r a t i o of the contractioii i n t h e b d i r c c -
'ab
tion t o extension i n t h e a d i r e c t i o n due t o a t e n s i l e s t r e s s i n the a d i r e c t i o n .
'ba
is s i m i l a r l y defined, and X = 1 - EJ. p.
a b ba
.
F o r i s o t r o p i c f a c i i r p s i[ w a s
a s s u m e d t h a t p = O. 25. F o r o r t h o t r o p i c facings i t was a s s u m e d that IJ. =
ab
= 0 . 2 , E ' = E ' and G ! = 0 . 2 1 E .
'ba a b' ba a
P a r a m e t e r s needed for use of the c h a r t of f i g u r e 5-1 a r e :
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
1. P a n e l a s p e c t r a t i o a / b o r b/a
lFcl, 2
2. Facing properties ~l
3. Ratio of E ' t / E i t l .
2 2
f T h e c h a r t s of f i g u r e s 5-1 to 5-22 a r e a l s o applicable t o sandwich with

d i s s i m i l a r facings w h e r e i n facing 1 is i s o t r o p i c (c1 = 1 . O , = 1 . O , and
= O. 375) and facing 2 is orthotropic ( a = 1. O , = O . 6 , and y = O . 2).
Y1 2 2
F o r s u c h a sandwich, l i n e a r interpolation is m a d e between c u r v e s for
sandwich with both facings i s o t r o p i c and c u r v e s f o r sandwich Lvith both
facings orthotropic by m e a n s of the p a r a m e t e r
1
E;t2/E't r =1t
1 1
*<Laminates giving the following values of Q , 6, and y w e r e of g l a s s f a b r i c s
112, 116, 120, 128, 162, 164, 181, 182, 183, and 184 ( r e f . 5-2).
5 -5

MIL-HDBK-23A CHG N O T I C E 3 = 9999970 0347979 TbO
--
Values of T = O c o r r e s p o n d t o sandwich with both facings i s o t r o p i c and

T = 1 t o sandwich with both facings orthotropic. T h i s is d e m o n s t r a t e d by
s u b s t i t u t i o n of t h e s e T values i n the g e n e r a l e x p r e s s i o n f o r K ( r e f . 5-3).
M
Thus f o r example: i f T = 1 / 4 , interpolation is at 1 / 4 of the d i s t a n c e f r o m
t h e c u r v e f o r both facings i s o t r o p i c toward t h e c u r v e f o r both facings
Ort hotsopic.
5. 3 . 2 Determination of Actual Values of h
Since a c t u a l c o r e s h e a r modulus values a r e not v e r y l a r g e , a value of

h somewhat g r e a t e r than given on f i g u r e 5-1 m u s t be used. C h a r t s f o r I
d e t e r m i n i n g h f o r sandwich with all edges s i m p l y supported a r e shown in

f i g u r e s 5-2, 5-3, 5 - 4 , 5 - 5 , and 5 - 6 . T h e s e figures a r e e n t e r e d with values
of t h e panel a s p e c t r a t i o and v a l u e s of V a6 computed by equation (5: 5) o r
(5:5a). F i g u r e 5-2 applies t o sandwich with i s o t r o p i c c o r e s f o r which the
c o r e s h e a r modulus perpendicular t o t h e d i r e c t i o n of loading is equal to the
c o r e s h e a r modulus p a r a l l e l to t h e d i r e c t i o n of loading. F i g u r e 5 - 3 applies
t o sandwich'with honeycomb c o r e s f o r which the c o r e s h e a r modulus p e r -
pendicular t o t h e d i r e c t i o n of loading is equal t o O . 40 t i m e s the c o r e s h e a r
modulus p a r a l l e l t o t h e d i r e c t i o n of loading. F i g u r e 5 - 4 applies t o sandwich
with honeycomb c o r e s f o r which the c o r e s h e a r modulus perpendicular t o
the d i r e c t i o n of loading is 2. 50 times t h e c o r e s h e a r modulus p a r a l l e l t o the
d i r e c t i o n of loading.
NOTE: F o r honeycomb c o r e s with c o r e ribbons p a r a l l e l

t o d i r e c t i o n of loading, C
C
-
G T L and the s h e a r modulus
perpendicular t o loading is G F o r honeycomb c o r e s
TW'
with c o r e ribbons perpendicular t o d i r e c t i o n of loading
G = C T w and t h e s h e a r modulus perpendicular t o l o a d -
C
ing is C
TL'
F i g u r e 5 - 5 applies t o sandwich with c o r r u g a t e d c o r e having the c o r e
f l u t e s perpendicular t o the d i r e c t i o n of loading. F i g u r e 5-6 applies t o s a n d -
wich with c o r r u g a t e d c o r e having t h e c o r e flutes p a r a l l e l to the d i r e c t i o n of
loading and r e q u i r e s values of the p a r a m e t e r W given by equation (5:6) o r
(5: 6a) i n s t e a d of values of V.
In using f i g u r e s 5 - 2 , 5 - 3 , 5 - 4 , 5 - 5 , and 5-6: i t is n e c e s s a r y t o i t e r a t e

b e c a u s e V is d i r e c t l y proportional t o the c o r e thickness t . A s an aid to
C
finally d e t e r m i n i n g t and G , f i g u r e 5-7 p r e s e n t s a n u m b e r of l i n e s r e p r e -
C C
senting V f o r v a r i o u s values of C with V ranging f r o m 0 . 0 1 to 2 and G
C C
ranging f r o m 1 , 0 0 0 t o 1 , 0 0 0 , 0 0 0 pounds per s q u a r e inch. The following
p r o c e d u r e is suggested:
5 -6
-
.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-____ . - ~-
1. Determine a core thickness t f r o m f i g u r e 5-2, 5-3, 5-4, 5-5, o r

C
5-6 using a value of 0 . 0 1 f o r V o r W .
2. Compute t h e constant r e l a t i n g V o r W to G
C
.
r '
IT
2
t E't E't
c 1 1 2 2 1 (for equal facings)
=VC orWG
C C
3. With this constant e n t e r f i g u r e 5-7 and d e t e r m i n e n e c e s s a r y G

C
.
4. ' I f the s h e a r modulus is outside the r a n g e of values f o r m a t e r i a l s
available, s l i d e up t h e a p p r o p r i a t e line of f i g u r e 5-7 and pick a new value of
V o r W , for a r e a s o n a b l e value of c o r e s h e a r modulus.
5. R e e n t e r f i g u r e 5 - 2 , 5 - 3 , 5-4, 5 - 5 , o r 5-6 with t h e new value of V

o r W and r e p e a t previous s t e p s 1, 2 , and 3.
C h a r t s of the type used in f i g u r e s 5 - 2 , 5-3, 5 - 4 , 5 - 5 , and 5-6 have not

been p r e p a r e d for panels with ends o r s i d e s clamped. T r u e clamping a t
panel edges is n e v e r attained, p a r t i c u l a r l y f o r sandwich constructions. It
is suggested that e a c h panel be designed as s i m p l y supported on a l l edges
and then e n t e r f i g u r e 5-1 to e s t i m a t e any possible reduction that can be
m a d e i n c o r e t h i c k n e s s due to edge clamping.
5 . 3 . 3 Checking P r o c e d u r e f o r Determining
Buckling S t r e s s ' , F
cr
T h e d e s i g n s h a l l be checked by using the g r a p h s of f i g u r e s 5 - 8 t o 5-21
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
t o d e t e r m i n e values of K f o r u s e i n evaluating K = K t KM to substitute
M F
into f o r m u l a (5:Z) o r (5:2a) to compute actual buckling s t r e s s , F
cr
.
The f i g u r e s apply to sandwich panels with e d g e s s i m p l y supported and
c l a m p e d and to sandwich with i s o t r o p i c o r c e r t a i n o r t h o t r o p i c facings and
cores (see 5.3. i).
5 -7

NIL-HDBK-23A CHG N O T I C E 3 9999970 0147981 b19 M
F o r e a c h value of t h e p a r a m e t e r V , t h e r e is a cusped c u r v e giving values

of K f o r v a r i o u s values of t h e r a t i o s a / b o r b / a . T h e s e c u s p s a r e indicated
M
by dotted l i n e s f o r t h e t o p c u r v e i n e a c h f i g u r e . T h e c u s p s show the s a n d -
wich panel buckling coefficients calculated f o r d i f f e r e n t values of n, the n u m -
b e r of half waves i n t o which t h e panel buckles. Only the portions of e a c h
c u s p e d - c u r v e f o r which K is a m i n i m u m a r e shown. Envelope c u r v e s i n d i -
M
c a t e values of K f o r u s e i n design.
M
Values of K s h a l l be d e t e r m i n e d by t h e f o r m u l a
F
[ E 1' t 31 t E i t ; ) ( E i t l t E > t 2 )
(5: 7)
7
KMO
12E't E ' t hL
1 1 2 2
2
t
( f o r equal facings) (5: 7a)
K F = 2 KMO
3h
where K is d e t e r m i n e d f r o m t h e c h a r t of f i g u r e 5-22. (KMo = KM when

MO
V = O .) F o r panels with a / b r a t i o s l a r g e r than shown on f i g u r e 5-22, i t _- -.
c a n be a s s u m e d that K = O . Then K s h a l l be computed as K t K -

F F M - KM
and equation (5:2) and (5:2a) solved f o r F
cr
.
It should be understood that
if t h e d e s i r e d F is above p r o p o r t i o n a l limit v a l u e s , the value of E ' s h a l l
cr
be a n effective v a l u e , used i n computing V and F
cr
.
If t h e c h a r t s d o not apply b e c a u s e r a t i o s of c o r e s h e a r moduli a r e far
different f r o m what is given on t h e c h a r t s , o r it is d e s i r e d t o c h e c k by a
m o r e a c c u r a t e a n a l y s i s , t h e f o r m u l a s given i n t h e following s h a l l be used
(refs. 5-1, 5 - 2 , 5-3):
+ K t
1 2 [ 1 t - B V
2
(5:8)
R 2
+2 t + Q V t -B2V
3 2 C
4
( 5 : 9)
..~.- ~
5 -8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-- - ~ _ _
~ - _ _
NIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 7 7 0 0347982 555 M
where
B
K1 -2
$,= T t (1 - T)K. ( 5 : 10)
2 1
B
2 12 2 B2
$2= T t 2T(1 - T)-+
B
(1 - T) - ( 5 : 1 1)
1 B1
, +3 = T t (1 - T)-*
*, B2
- (5: 12)
Q2 B1
Bi = c1c3 - Bi c + y c K
2 i 2 i
( 5 : 13)
(5: 14)
Q = Q C &+ (+t)yic2+; C
3
(5: 15)
i i l c
4 i
T h e p a r a m e t e r s of t h e s e f o r m u l a s a r e given by t h e following e x p r e s s i o n s :
A 1,
T = (5: 16)
+ A2
2
r t
A1A2 C
V = ( 5 : 17)
A2 b2G
ca
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C
R = - ca ( 5 : 18)
C
cb
(5: 19)
where G and G a r e the moduli of t r a n s v e r s e r i g i d i t y of t h e c o r e a s s o -

cb ca
c i a t e d with t h e d i r e c t i o n s of t h e loaded and unloaded edges of t h e panel.
5 -9

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 7 9 7 0 0 3 4 7 9 8 3 491
The values of c c c and c d e p e n d upon t h e panel a s p e c t r a t i o ,

1 2 3 4
b / a , t h e i n t e g r a l number of longitudinal half waves, n, into which the panel
buckles, and the panel edge conditions. Values of n a r e chosen to produce
m i n i m u m values of N.
For a panel with a l l edges s i m p l y supported:
2 2 2
n b
c = c =- a c = 1, and c = -
1 4 22 2 3 2
n b a
F o r a panel with loaded edges s i m p l y supported and other edges clamped:
F o r a panel with loaded edges clamped and other edges s i m p l y supported:
2 4 , 2 .
bz
L
2
t lib n + I a
F o r a panel with a l l edges clamped:
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Adaptations of t h e s e f o r m u l a s to sandwich with c o r r u g a t e d c o r e a r e

m a d e by considering c o r e s h e a r modulus infinite i n the d i r e c t i o n of the c o r -
rugation flutes ( d e t a i l s i n r e f . 5-2). If the c o r r u g a t i o n flutes a r e p a r a l l e l
t o the d i r e c t i o n of loading, they c a n c a r r y load i n proportion t o t h e i r a r e a
and e l a s t i c modulus.
5-10

MIL-HDBK-23A CHG N O T I C E 3 E 9979970 0347984 328
F o r panels with edges a not s i m p l y supported but supported by b e a m s

with low t o r s i o n a l rigidity but finite bending s t i f f n e s s , the buckling coeffi-
c i e n t m a y be m u c h low.er than f o r panels with simply supported edges
( r e f . 5-6). T h e buckling coefficient f o r s u c h a panel is dependent upon the
p a r a m e t e r s 5 and @ in addition t o t h e u s u a l p a r a m e t e r s w h e r e 5 and e
depend upon bending s t i f f n e s s and c r o s s s e c t i o n a l a r e a of the b e a m s u p p o r t s .
C h a r t s showing effects of b e a m support s t i f f n e s s and a r e a on buckling coeffi-
c i e n t s a r e given in f i g u r e s 5-23 and 5-24.
(5- 1) ERICKSEN, WILHELM S . , and MARCH, H. W .

1958. Effects of S h e a r Deformation i n the C o r e on a F l a t Rectangu-
lar Sandw.ich P a n e l . U . S . F o r e s t P r o d . Lab. Rep. 1 5 8 3 - B .
Rev.
JENKINSON, P A U L M . , and KUENZI, EDWAARD W .

1965. Buckling Coefficients f o r F l a t Rectangulr Sanckvich P a n e l s
with C o r r u g a t e d C o r e s Under EdgeLvise C o m p r e s s i o n .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
U . S . F o r e s t S e r v . R e s e a r c h P a p e r FPL 2 5 . F o r e s t P r o d .
Lab. , Madison, M'is .
KUENZI, EDW-'ARD U'. , NORRIS, CHARLES B . ! and
JENKINSON, PAUL M.
1964. Buckling Coefficients f o r Simply Supported and Cizmped Fiat.
Rectangular Sandlvich P z n e l s Under Edgets i c e C o r - p r e s s i o n .
U . S . F o r e s t Sers;. R e s e a r c h Note FFL-OTO. F o r e s t Proci.
Lab. , Madison, Wis.
(5-4) NOR R I S , CHARLES B.

1958. C o m p r e s s i v e Buckling C u r v e s f o r Simply Supported Sandlvich
P a n e l s Lvit'n G l a s s - F a b r i c - L a m i n a t e Facings and Honeycomb
C o r e s . U . S . F o r e s t P r o d . Lab. Rep. 1867.

Current Metallic M a t e r i a l s and E l e m e n t s f o r A e r o s p a c e V e h i c l e s
S t r u c t u r e s . M i l i t a r v Handbook 5 , Available f r o m V . C . Gov.
P r i n t i n g Office, Washington D. C.
(5-6) ZAHN, JOHN J., and CHENG, S H U K

1964. Edgewise C o m p r e s s i v e Buckling of Flat Sandxxich P a n e l s :
Loaded E n d s Simply Supported and Sides Supported by- B e a m s .
U . S . F o r e s t S e r v . R e s e a r c h Note F P L - 0 1 9 . F o r e s t P r o d .
Lab., Madison, W i s .
5-1 1

MIL-HDBK-23A CHG N O T I C E 3 I9777770 0347785 264 W
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
3.0/
3.02
O.03
3.04
0.05 -1-
3.06
0.07
/ i / 1 --- BO r H FACINGS OR THOTROPIC 0.08

0.03; /
I
I
i
{FOR DISSIMIL AI? FACINGS SEE 5.3.11
o. o9
o./o
F i g u r e 5-1. - - C h a r t for d e t e r m i n i n g h / b r a t i o ( V = O) s u c h that a s a n d -

wich panel w i l l not buckle under edgewise c o m p r e s s i o n load.
- _ - - - - Y
_-_ _
~ ---
- _
Provided by IHS
_ ~ - Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
a
b "i
60 TH FACINGS IS0 TROPIC

60TH FACINGS ORTHOTROPIC
! /FOR DISSIMILAR FACINGS SEE 5.3.1)
F i g u r e 5-2. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y s u p -
p o r t e d sandwich panel with i s o t r o p i c c o r e ( G = G ) w i l l not buckle
cb ca
under edgewise c o m p r e s s i o n lad.
-------;_ --
t
c
- P
-
MIL-HBBK-23A C H G N O T I C E 3 = 9999970 0347987 037
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 5-3. - - C h a r t for d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y s u p -

p o r t e d sandwich panel with o r t h o t r o p i c c o r e (G = 0.4 G ) w i l l not
cb ca
buckle under edgewise c o m p r e s s i o n load.
-----__
--__
---
r
-
--_
MIL-HDBK-23A CH6 N O T I C E 3 E 9 9 7 9 9 7 0 0 3 4 7 9 8 8 T 7 3 E
f
I
b
I
I
F i g u r e 5-4. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y s u p -
p o r t e d sandwich panel with o r t h o t r o p i c c o r e (G = 2.5 C ) w i l l not
cb ca
- -_buckle under e d g e w i s e c o m p r e s s i o n load.
- ~ .
~
-- .
- ..
_-
_- --`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-----__ - __-
m
~
MIL-HDBK-23A CHG N O T I C E 3 9999970 0347989 9 0 T m
F i g u r e 5-5. - - C h a r t for d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y sup-

p o r t e d sandwich p a n e l with c o r r u g a t e d c o r e w i l l not buckle under
e d g e w i s e c o m p r e s s i o n load; c o r e c o r r u g a t i o n f l u t e s p e r p e n d i c u l a r
t o load d i r e c t i o n .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- - __
MIL-HDK-234 CHG N O T I C E 3 H 9999970 0347990 621 H
t oo
I
F i g u r e 5-6. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y sup-

ported sandwich panel with c o r r u g a t e d c o r e w i l i not buckle under
edgewise c o m p r e s s i o n load; c o r e c o r r u g a t i o n flutes p a r a l l e l t o load
d i r ec t ion.
___c_----- --
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~~-
MIL-HDBK-23A C H d N O T I C E 3 9999970 OL4799L 568 M
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
M &O A

= 9999970 0347q92 4 T 4 = __ -
._
_I----
- 00TH
LEGEND:
FA CINGS /so R o w c r
-- BOTH FACINGS o f v H o r R o P i c
/FOR DISSIMIL AR FACINGS SEE 5.3.I/
0-
O
b
F i g u r e 5-8. --K for sandwich panel with ends and s i d e s s i m p l y s u p -

M
p o r t e d and o r t h o t r o p i c c o r e , (Gcb = 2.5 G c a ).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CMG N O T I C E 3 m 9 9 9 9 9 7 0 0347993 330 W
/4
GC
/o END
LEGEND:
- BOTH FACINGS ISOTROPIC
-- BOTH FACINGS ORTHOTROPIC
/FOR DISSIMI AR FACINGS SEE 5.3.I)
O
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
o -
6
F o
F i g u r e 5-9. --K for sandwich panel with e n d s and s i d e s s i m p l y sup-

M
p o r t e d and i s o t r o p i c c o r e . (Ccb = Go).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_____ -
MIL-HDBK-23A CHG N O T I C E 3 = 9999970 0347994 2 7 7 =
I4 I
I
I
I
v=o
I2
/o
LEGEND:
8 - BOTH FACINGS ISOTROPIC
-- BOTH FACINGS Off THOTROPIC
/FOR DISSIMIL A ff FACINGS SEE 5.3.11
&?
6
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O
-
0 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
F i g u r e 5-10. --K f o r sandwich panel w i t h ends and s i d e s simply s up-

M
(Gcb = 0 . 4 G ).
p o r t e d and o r t h o t r o p i c c o r e .
. ca

= 7977770 OLL17775
-
HIL-HDBK-23A C H G N O T I C E 3 LO3
/4
/2
/O
~ -.
2
TH FACINGS /SOTROP/C
00TH FACINGS OU THO TUOF/C
(FOU DlSS/MlLAU FACINGS SEE 5.3.11
-
U b
b 0
Figurc 5-11. --K for sandwich panel with ends s i m p l y s u p p o r t e d and

LM
sides ciamped, and o r t h o t r o p i c c o r e . (Gcb = 2 . 5 G ).

ca
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0347996 O 4 T m
I4
I2
IO
C
O
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 5-12. --K f o r sandwich panel with ends s i m p l y supportel. ant

M
sides c l a m p e d , and i s o t r o p i c c o r e . {Ccb = Cca).

~~
MIL-HDBK-23A CHG N O T I C E 3 9999970 0147997 TBb
-/4
III I I I
LEGEND:
BO r H FACINGS isorRoPIc
BOTH FACINGS oRrHort?oPIc
(FOR /SS/MILAR FACINGS SE 5.3.1)
/2
/O
01
4 6
b a
F i g u r e 5 - 1 3 . --K f o r sandwich panel with ends s i m p l y s u p p o r t e d and

M
$$des c l a m p e d , and o r t h o t r o p i c c o r e . (Gcb = 0.4 C ).
ca
-- ---
- Y
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
-
MIL-HDBK-23A
. -
CHG N O T I C E 3
~ _ _ _
9999970 0147998 912

~
- eoTH FA CIN GS IS o TR oP c
LEGEND : +--
-- cow FACINGS o ~ r ~ o r ~ o p i c
(FOR DISSIMIL AR FACINGS SEE 5.3.// +
I
F i g u r e 5-14. --KM for sandwich panel with ends clamped and s i d e s

s i m p l y s u p p o r t e d , and o r t h o t r o p i c c o r e , (Gcb = 2. 5 G c a).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

/4 I I I I
l l
-
LEGEND:
BOTH FACINGS ISOTROPIC
-
-- BOTH FACINGS ORTHOTROPIC
f FOR DISSIMIL AR FA CINGS SEE 5.3.I /
o- I I I I l I
-
a -
6
6 a
F i g u r e 5-15. --K f o r sandwich panel with ends c l a m p e d and s i d e s

M
s i m p l y s u p p o r t e d , and i s o t r o p i c c o r e . ( G c b = Gca).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-__
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 OL48000 179 m
LZGEND :
- BO Tff FAC/NGS /SO TROPIC
--- 00r H FACINGS OR THO TROPIC
/FOR DISSIMIL A ff FACINGS SEE 5.3.1)
/2
-
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
Figure 5-16. --K for sandwich panel with ends clamped and sides
M
simply supported, and orthotropic core. ( G c b = 0 . 4 G ).
ca
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_____~ ~-
MIL-HDBK-23A CHG NOTICE 3 9999970 O148001 005
LEGEND:
BOTH FA C I N G S I S 0 TROP/C
BOTH FACINGS OR?-HOTROPIC
fFOff D/SS/MIL Aff FACNGS SEE 5.3.1)
n
-0
L L
0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2
~~
O
U -
b
b O
F i g u r e 5-17. sandwich panel with ends and s i d e s c l a m p e d ,

- -KM for
and o r t h o t r o p i c c o r e . ( G c b = 2.5 C
Ca).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-~ -__ --_-
flIL-HDBK-23A CHG N O T I C E 3 M 9999970 0 3 4 8 0 0 2 " 4 3
I l I
v=o
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
----i-
-----
2-
LEGEND:
- rii
00 FACINGS is0 mom
-- BOW FACINGS O t i w o r R o P I c .
fFOff DISSIMIL AR FACINGS SEE 5 . 3 . I )
n I I I I 1 I
-0 0.2 0.4 0.6 0.8 1.0 0.8 0.6 0.4 0.2 O
b
o -b
o
F i g u r e 5-18. --K for sandwich panel with ends and s i d e s c l a m p e d ,

M
and i s o t r o p i c c o r e . (Ccb = Gca).

~ _ _
_ _ _ ~
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 7 9 7 0 OLLI8003 988 m
I
I - - z
I j I
I
--== I
I I
I I
I
/SO TROPE i
F i g u r e 5-19. --K for sandwich panel with ends and s i d e s c l a m p e d ,

M
and o r t h o t r o p i c c o r e . ( C c b = O. 4 C ).
ca
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 = 9999970 OLLIBOOLI 8LLI W
/4
l n I l I I
I v=o
i L EGEN :
-
--
00 r H FACINGS /soruop/c
BOTH FACINGS ORTHOTROPIC
(FOR / S S / M / i A R FACINGS SEE 5.3.
/O
O
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
-4
b
-
6
4
F i g u r e 5-20. --K f o r s i m p l y supported sandwich panel having a c o r r u -

M
gated c o r e . C o r e c o r r u g a t i o n f l u t e s p e r p e n d i c u l a r t o load direction.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HDBK-23A CHG N O T I C E 3 H 9999970 OL4OOS 750 W
I I I
LEGNU:
-
-
--
00 w FACINGS is0 mowc
BOTH FACINGS om-HorRoP/c
(FOR UISS/M/LA ff FA C/NGS S 5.3.//
I .-.......---....n = 2 .....n = 3 O
\ n=/
1
_...-- . . ._.-. /
O.I
/
(0.2
-0 H
.0.4, O./
\
,0.2
O. 4
O
-
O
I
0.2 0.4 0.6 0.8 /.O 0.8 0,s 0.4 0.2 O
F i g u r e 5-21. --K f o r s i m p l y s u p p o r t e d sandwich panel having a c o r r u -

M
gated c o r e . C o r e c o r r u g a t i o n f l u t e s p a r a l l e l to load d i r e c t i o n .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-- ~ _ ~ - _ _ _
MIL-HDBK-23A CHG N O T I C E 3 m 9997970 0BL)BOOb b97 m
t
___t!
\ \ 0 4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
/O
9
8
7
!
(FOR DSSIMIL AR FACINGS SEE 5.3.11 I
3
-
O./ 0.2 0.3 0.4 0.5 0.6 0.8 /.O
u
-
b
Figure 5-22, - - V a l u e s Of K for s a n d w i c h panels i n e d g e w i s e com-
MO
pres sion.

MIL-HDBY-23A CHG N O T I C E 3 E 9 9 9 9 9 7 0 O348007 5 2 3 W
7 ,I
LE G Z " :
-c = 00
---( = 25
-
.....-5 /o
.. ==G!3,
6 OR O
5
LOADED ENDS
S/MPL Y SUPPORTED
I \
k
I
'\
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
3
#=I,3 OR 5
I'
i
.
I
C
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
-
U b
-
6 a
F i g u r e 5-23. --Edgewise c o m p r e s s i v e buckling coefficients f o r f l a t ,

i s o t r o p i c , sandwich panels with loaded ends s i m p l y supported and
s i d e s supported by b e a m s ; p = O . 3; V = O.

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
OR 5
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O

-
U b
-
b U
F i g u r e 5-24. - - E d g e w i s e c o m p r e s s i v e buckling coefficients f o r f l a t ,

i s o t r o p i c , sandwich panels with loaded ends s i m p l y s u p p o r t e and
s i d e s supported by b e a m s ; p. = O. 3; V = O. 1.

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0348009 3 T b
MIL - HD BK - 23A
30 Dec 1968
CHAPTER 6
DESIGN O F F L A T RECTANGULAR SANDWICH PANELS UNDER
EDGEWISE SHEAR LOAD
6. 1 BASIC PRINCIPLES
A s s u m i n g t h a t a d e s i g n begins with c h o s e n d e s i g n s t r e s s e s and a given

load t o t r a n s m i t , a flat r e c t a n g u l a r panel of sandwich c o n s t r u c t i o n under
edgewise s h e a r load s h a l l be d e s i g n e d t o comply with t h e four b a s i c d e s i g n
p r i n c i p l e s s u m m a r i z e d i n 1.2 of Introduction. T h e s e four conditions m u s t
be met.-
O v e r a l l buckling of t h e sandwich o r dimpling o r wrinkling of t h e facings

cannot o c c u r without possible t o t a l c o l l a p s e of t h e panel. Detailed p r o c e -
d u r e s giving t h e o r e t i c a l f o r m u l a s and g r a p h s for d e t e r m i n i n g d i m e n s i o n s of
the facings and c o r e , as w e l l as n e c e s s a r y c o r e p r o p e r t i e s , a r e given i n
following p a r a g r a p h s . Double f o r m u l a s a r e given, one f o r m u l a f o r s a n d -
wich with facings of different m a t e r i a l s and t h i c k n e s s e s and another f o r m u l a
f o r sandwich with e a c h facing of the s a m e m a t e r i a l and t h i c k n e s s , F a c i n g
modulus of e l a s t i c i t y , E ' ; s h e a r m o d u l u s , G ' ; and s t r e s s v a l u e s F , s h a l l
S
be v a l u e s at the conditions of u s e ; f o r e x a m p l e , i f application i s a t e l e v a t e d
t e m p e r a t u r e , then facing p r o p e r t i e s a t e l e v a t e d t e m p e r a t u r e s h a l l be u s e d
i n design. T h e facing s h e a r modulus o r modulus of e l a s t i c i t y i s the effective
v a l u e at t h e facing s t r e s s . If t h i s s t r e s s is beyond the p r o p o r t i o n a l l i m i t
v a l u e , a n a p p r o p r i a t e tangent, r e d u c e d , o r modified value s h a l l be u s e d
(ref. 6-4).
tlFsl
+ t 2 Fs 2 = N
S
(for unequal facings) (6: 1)
N
S
t=- (for e q u a l f a c i n g s ) (6: la)
2F
S
6-1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9999970 O L 4 O L O O L
w h e r e t is facing thickness; F is chosen design facing s h e a r s t r e s s ; N

S S
is design s h e a r load p e r unit length of panel edge; and 1 , 2 a r e - s u b s c r i p t s
denoting facings 1 and 2.
In determining t h i c k n e s s e s of facings f o r sandLvich Lvith facings of d i f f t r -

ent m a t e r i a l s , equation (6: 1) m u s t be s a t i s f i e d , but a l s o the s t r e s s e s F
s1
and F m u s t be chosen s o t h a t F s l / G s l - F s 2 / G s 2 (where G is facing
s2 S
s e c a n t s h e a r modulus), thus avoiding o v e r s t r e s s i n g of e i t h e r facing. F o r

e x a m p l e , i f facing 1 is a material s u c h t h a t F = 0 . 0 0 5 , and facing 2
s l/Gs 1
is a material s u c h t h a t F = 0.002, the design m u s t be b a s e d on a
s2/Gs2
r a t i o of F = O . . O O Z , otherwise facing 2 \cil1 be o v c r s t r c s s e d .
s d G s l = Fs2/Gs2
In o r d e r t o a c c o m p l i s h t h i s , the chosen design s t r e s s f o r facing 1 m u s t be
lowered. F o r m a n y combinations of facing m a t e r i a l s it w i l l be found advan-
tageons t o c h o o s e t h i c k n e s s e s s u c h t h a t G t = G t o r E t = E t
1 1 2 2 1 1 2 2
6. 3 DETERMINING CORE THICKNESS
AND CORE SHEAR MODULUS
T h i s section gives p r o c e d u r e s f o r d e t e r m i n i n g c o r e thickness and c o r e _--

s h e a r modulus s o t h a t o v e r a l l buckling of the sandwich panel w i l l not o c c u r
( r e f s . 6- 1 and 6-2). T h e load p2r unit panel width at which buckling of a
sandwich panel w i l l o c c u r i s given by the f o r m u l a :
w h e r e D is sandwich bending s t i f f n e s s . This f o r m u l a solved f o r the facing

s t r e s s becomes:
.
(6: 2)
2
( f o r equal facings) (6: 2 a )
6-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 H 9 9 9 9 9 7 0 O L 4 8 O L L T 5 Y H
2
w h e r e E' is effective modulus of e l a s t i c i t y of facing a t s t r e s s F ; X = 1
S
- p ;
p is P o i s s o n ' s r a t i o of facings (in f o r m u l a (6:2) it is a s s u m e d that p = -
p1-
p2); h is d i s t a n c e between facing c e n t r o i d s ; b is width of panel; K = K + KM;
F
K is a t h e o r e t i c a l coefficient dependent on facing stiffness and panel aspect
F
ratio; K is a t h e o r e t i c a l coefficient dependent on sandwich bending and
M
s h e a r r i g i d i t i e s and panel a s p e c t r a t i o .
Solving equations (6:Z) and (6:Za) f o r h / b gives

/ \
(6: 3)
X F
-h= (for equal facings) (6: 3a)
h
T h e r e f o r e , if K is known, equations (6:3) o r (6:3a) c a n be solved d i r e c t l y

t o eventually obtain h because all other quantities a r e known. After h is
obtained, the c o r e t h i c k n e s s , t , is computed f r o m t h e formiilas
C
t = h -
+ 5 (6: 4)
C 2
t = h - t (for equal facings) ( 6: 4a)

C
As a first approximation, it w i l l be a s s u m e d that K = O , hence K =

KM' F
Values of K depend upon the bending and s h e a r rigidities of the sandwich
M
2
.rrD
as i n c o r p o r a t e d i n the p a r a m e t e r V = -, which can be written a s :
b2U
2
TI t E't E't
c 1 1 2 2
V = 1 ( 6 : 5)
Xb'G (E;tl t E i t 2 )
C
6-3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

2
ir t E't
C
V = ( f o r equal f a c i n g s ) (6:5a)
2
2Xb G
C
w h e r e U is sandwich s h e a r s t i f f n e s s ; G i s the c o r e s h e a r modulus a s s o c i a t e d

C
with t h e axes p a r a l l e l t o panel side of length a and perpendicular t o the plane
of t h e panel. A s values of c o r e s h e a r modulus d e c r e a s e , values of V i n c r e a s e
and values of K gradually d e c r e a s e .
M
F o r sandwich with c o r r u g a t e d c o r e having c o r r u g a t i o n f l u t e s p a r a l l e l t o
the edge of length a , t h e p a r a m e t e r V is r e p l a c e d by t h e p a r a m e t e r
2
n t D r.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
which c a n be w r i t t e n as: 3
rLt E't E't

c 1 1 2 2
W = 7 (6: 6)
XbLG ( E ; t l + E i t z )
cb
2
n t E't
c
W = ( f o r equal facings) (6: 6a)
2
2Xb G c b
where G is t h e c o r e s h e a r modulus a s s o c i a t e d with t h e a x e s p a r a l l e l t o

Cb
t h e edge of length b and perpendicular t o the plane of the panel ( r e f . 6 - 1).
6. 3 . 1 Determination of Minimum Values of h
A m i n i m u m value of h r e q u i r e d w i l l be d e t e r m i n e d by a s s u m i n g V = O o r
W = O , f o r a f i r s t approximation. The value of h is m i n i m u m because 'V = O
o r W = O only i f t h e c o r e s h e a r modulus is infinite; f o r any a c t u a l c o r e t h e
s h e a r modulus is not infinite, hence a t h i c k e r c o r e m u s t be used. T h e
c u r v e s f o r V = O o r W = O i n t h e c h a r t s of f i g u r e s 6-1 to 6-5 give m i n i m u m
values of h f o r sandwich panels with i s o t r o p i c , o r t h o t r o p i c , o r c o r r u g a t e d
c o r e s and with s i m p l y supported edges. P a n e l s with clamped edges a r e not
included i n t h e d e s i g n c h a r t s b e c a u s e t r u l y clamped edges a r e not actually
a t t a i n a b l e . Approximate c u r v e s f o r checking c l a m p e d sandwich a r e included
and d i s c u s s e d i n 6. 3 . 3.
6-4
--------

NIL-HDBK-23A CHG N O T I C E 3 E 9999970 0348033 8 2 7
The c h a r t s of f i g u r e s 6-1, 6-2, and 6 - 3 are applicable t o s i m p l y s u p p o r t e d

sandwich with i s o t r o p i c facings f o r which (Y = 1. O; 6 = 1. O; y = O. 375, and t o
sandwich with o r t h o t r o p i c f a c i n g s s u c h as g l a s s f a b r i c l a m i n a t e s * f o r which
(Y = 1. O; @ = O. 6; and y = O. 2.
. T h e constants (Y, 6, and y depend upon t h e e l a s t i c p r o p e r t i e s of the

f a c i n g s , as follows:
w h e r e E' and E ' are t h e moduli of e l a s t i c i t y p a r a l l e l t o s i d e s a and b,

a b
r e s p e c t i v e l y ; G ' is the facing s h e a r modulus a s s o c i a t e d with t h o s e d i r e c -
ba
t i o n s ; p . is t h e P o i s s o n ' s r a t i o of the c o n t r a c t i o n i n t h e b d i r e c t i o n t o
ab
extension in the a d i r e c t i o n due t o a tensile s t r e s s i n the a d i r e c t i o n ; r ~ .
ba
is s i m i l a r l y defined; and A = 1 p p
ab ba
- .
F o r i s o t r o p i c facings i t w a s
a s s u m e d that p = 0.25. F o r o r t h o t r o p i c facings i t w a s a s s u m e d that p, =
ab
'ba
= 0 . 2 , E ' = E;, and G ' = O. 2 1 E
a ba a
.
P a r a m e t e r s needed f o r the use of t h e c h a r t s i n f i g u r e s 6-1, 6 - 2 , and
6-3 are:
1. Panel aspect ratio b / a

A F
sl,2
2. Faciqg properties
E'
1, 2
E22
3. Ratio -
E' t
1 1
The c h a r t s of f i g u r e s 6-1, 6-2, and 6 - 3 a r e a l s o applicable to sandwich

with d i s s i m i l a r facings w h e r e i n facing 1 is i s o t r o p i c ( ( Y = 1. O , 8, = 1. O ,
1
y = O. 375) and facing 2 is o r t h o t r o p i c ( ( Y
2
= 1. O , fi2 = O. 6, y 2 = O. 2). F o r
s u c h a sandwich, l i n e a r i n t e r p o l a t i o n is m a d e between c u r v e s f o r sandwich
with both facings i s o t r o p i c and both facings o r t h o t r o p i c by m e a n s of the
parameter:
* L a m i n a t e s giving t h e following values of (Y, 6, and y w e r e of g l a s s f a b r i c s

112, 116, 120, 128, 162, 164, 181, 182, .183, and 184 (ref. 6-3).
6-5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HDBK-23A CHG N O T I C E 3 9999970 0148014 7 6 3 =
Values-of T = O c o r r e s p o n d to sandwich with both facings i s o t r o p i c and

T = 1 t o sandwich with both facings o r t h o t r o p i c . T h i s is d e m o n s t r a t e d by
substitution of t h e s e T v a l u e s i n t h e g e n e r a l e x p r e s s i o n f o r K (ref. 6-2).
M
T h u s , f o r e x a m p l e : If T = 1 / 4 , interpolation is at 1 / 4 of the d i s t a n c e f r o m
t h e c u r v e f o r both facings i s o t r o p i c t o w a r d the c u r v e f o r both facings
o r t h o t r opi c.
6. 3. 2 D e t e r m i n a t i o n of Actual Values of h
Since a c t u a l c o r e s h e a r modulus v a l u e s a r e not v e r y l a r g e , a value of

h s o m e w h a t g r e a t e r t h a n given by t h e c u r v e s for V = O o r W = O i n f i g u r e s
6-1 t o 6-5 must be used. T h e s e f i g u r e s a r e e n t e r e d with v a l u e s of t h e panel
a s p e c t r a t i o and v a l u e s of V o r W a6 computed by equations ( 6 : 5 ) , ( 6 : 5 a ) ,
( 6 : 6 ) , o r (6:6a). F i g u r e 6-1 applies t o sandwich with i s o t r o p i c c o r e s for
which t h e c o r e s h e a r modulus p e r p e n d i c u l a r to the panel length is equal to
t h e c o r e s h e a r modulus p a r a l l e l t o t h e panel length. F i g u r e 6-2 applies to
sandwich w i t h honeycomb c o r e s for which the c o r e s h e a r modulus p e r p e n -
d i c u l a r t o t h e panel length is O . 40 t i m e s the c o r e s h e a r modulus p a r a l l e l to
t h e panel length. F i g u r e 6 - 3 applies t o sandwicn with honeycomb c o r e s f o r
which t h e c o r e s h e a r modulus p e r p e n d i c u l a r t o t h e panel length is 2. 50
times t h e c o r e s h e a r modulus p a r a l l e l to the panel length.
NOTE: F o r honeycomb c o r e s with c o r e ribbons p a r a l l e l t o the

panel length, G - and t h e s h e a r modulus p e r p e n d i c u l a r t o
C G~~ -
panel length is G F o r honeycomb c o r e s with c o r e ribbons
TW'
p e r p e n d i c u l a r to t h e panel length, G
GTW C
-- and t h e s h e a r m o d -
ulus p e r p e n d i c u l a r t o the panel length is C
.r ~ '
F i g u r e 6-4 applies t o sandwich having i s o t r o p i c facings and a c o r r u g a t e d
c o r e with t h e c o r r u g a t i o n f l u t e s p a r a l l e l t o t h e edge of length a , The p a r a m -
e t e r W, given by equations (6:6) and (6:6a), i s used i n s t e a d of V . F i g u r e 6 - 5
a p p l i e s to sandwich having i s o t r o p i c facings and a c o r r u g a t e d c o r e with t h e
c o r r u g a t i o n flutes p a r a l l e l to t h e edge of length b. Solution of the c h a r t s
gives t h e r a t i o h / b .
6-6
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~-
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0348035 b T T
in using the c u r v e s of f i g u r e s 6-1 t o 6-5 f o r values of V o r W other than

z e r o , it is n e c e s s a r y to i t e r a t e b e c a u s e V and W a r e d i r e c t l y proportional
t o the c o r e thickness tc. As a n aid t o finally d e t e r m i n i n g t and C figure
C C'
6 - 6 p r e s e n t s a n u m b e r of l i n e s r e p r e s e n t i n g V o r W f o r v a r i o u s values of
G C., with V and W ranging f r o m O. O1 t o 2 and G C ranging f r o m 1 , 0 0 0 t o
1,000,000 pounds per s q u a r e inch. The following p r o c e d u r e is suggested.
1. D e t e r m i n e a c o r e thickness t f r o m f i g u r e s 6-1 to 6-5, using a

C
value of O. O1 f o r V o r W .
2. Compute t h e constant r e l a t i n g V o r W to G :
C
[ - r ~ t c E ; t l E ; t 2 )]
Xb ( E ' t t E > t 2
1 1
or
r-' t
2Xb
C
2
-
=VG
C
or WG
C
3. With this constant e n t e r f i g u r e 6 - 6 and d e t e r m i n e n e c e s s a r y G e

C
4. If t h e s h e a r modulus is outside the range of values for m a t e r i a l s

available, s l i d e up the a p p r o p r i a t e line of figure 6 - 6 and pick a new value of
V OP W f o r r e a s o n a b l e value of c o r e s h e a r modulus.
5. Reenter f i g u r e s 6-1 to 6-5 with the new value of V o r W and r e p e a t

previous s t e p s 1, 2, and 3 .
C h a r t s of t h e type used in f i g u r e s 6-1 through 6-5 have not been p r e p a r e d

f o r panels with ends o r s i d e s clamped. T r u e clamping at panel edges i s
never attained, p a r t i c u l a r l y f o r sandwich c o n s t r u c t i o n s . It i s suggested
that e a c h panel be designed as simply supported on all edges and consult
section 6. 3. 3 to e s t i m a t e any pDssible reduction that can be m a d e in c o r e
thickness due to edge clamping.
-
6.3.3 Checking P r o c e d u r e of Determining
Buckling S t r e s s , F
cr
The design s h a l l be checked by using the graphs of figures 6-7 to 6-11 to

d e t e r m i n e v a l u e s of K for u s e i n evaluating K = K t KM to substitute into
M F
f o r m u l a (6:2) o r (6:2a) and compute actual buckling s t r e s s , F
cr
The figures .
apply t o sandwich panels with edges simply supported and i s o t r o p i c o r c e r -
tain orthotropic facings and c o r e s . C u r v e s i n f i g u r e s 6 - 7 , 6-8, and 6 - 9 for
i s o t r o p i c facings and V # O w e r e d e r i v e d on the assumption that .p 1/4;and
i n f i g u r e s 6-10 and 6-11 that t~, = O . 3 .
6-7
-
-
*
Provided by IHS
-~ - -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HDBK-23A
-~
CHG N O T I C E 3 = 9999970 O L 4 8 0 L b 536

~ _ _ _ ~ _ _ _ _ _ _
Values of K s h a l l be d e t e r m i n e d by the f o r m u l a
F
(6: 7)
2
t
(for equal facings) (6:7a)
K F = 2 KMO
3h
where K is d e t e r m i n e d f r o m the c u r v e for V = O o r W = O of f i g u r e s 6-7

MO
to 6-11.
It should be understood that if the d e s i r e d F

is above proportional
cr
Limit v a l u e s , . t h e value of E ' s h a l l be a n effective value, used i n computing
V f r o m equation (6:5) o r (6:5a) o r W f r o m equation (6:6) o r (6:6a) and Fc r
f r o m equation (6:2) o r (6:2a).
-.
If the c h a r t s do not apply b e c a u s e r a t i o s of c o r e s h e a r moduli are far

different f r o m what i s given on the c h a r t s , o r i t i s d e s i r e d to check by a
m o r e a c c u r a t e a n a l y s i s , t h e f o r m u l a s given i n r e f e r e n c e s 6-1 and 6-2 s h a l l
be used.
G r a p h s of K for sandwich panels having i s o t r o p i c facings and i s o t r o p i c

M
o r o r t h o t r o p i c c o r e with all edges clamped a r e p r e s e n t e d i n f i g u r e s 6-12,
6-13, and 6-14. C u r v e s f o r clamped sandwich panels with orthotropic
c o r e s a r e approximate b e c a u s e they w e r e obtained by multiplying buckling
coefficients for simply supported orthotropic sandwich by the r a t i o of clamped
t o simply supported buckling coefficients for i s o t r o p i c sandwich. Values of
KM f r o m t h e s e f i g u r e s m a y be used to compute the facing s t r e s s F S f r o m
equation (6:2) o r (6:2a) o r t o s o l v e equation (6:3) o r (6:3a) f o r h / b . The
values of h / b s o obtained may then be c o m p a r e d with the values obtained for
s i m p l y supported panels given by the d e s i g n c h a r t s of f i g u r e s 6-1 t o 6-5 to
d e t e r m i n e possible reductions i n c o r e thickness due to edge clamping.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
6-8

-____
R E F E RENCE D DOCUMENTS
HAR RIS, L. A . , and AUE LMANN, R . R .

1959. Stability of Flat, Simply Supported C o r r u g a t e d C o r e Sandwich
P l a t e Under Combined Longitudinal C o m p r e s sion and Bending,
T r a n s v e r s e C o m p r e s s i o n and Bending, and S h e a r . North
A m e r i c a n Aviation, I n c . , M i s s i l e Div., Rep. STR 67.
KUENZI, E . W . , ERICKSEN, W . S . , and ZAHN, J. J .

1962. S h e a r Stability of Flat P a n e l s of Sandwich Construction.
NORRIS, CHARLES B.
1958. C o m p r e s s i v e Buckling Curves f o r Simply Supported Sandwich
P a n e l s with G l a s s - F a b r i c - L a m i n a t e Facings and Honeycomb
C o r e s . U.S. F o r e s t P r o d . Lab, Rep. 1867.
U.S. DEPARTMENT O F DEFENSE

Current Metallic M a t e r i a l s and Elements f o r AerosDace Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U . S . Gov.
P r i n t i n g Office, Washington, D. C .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
6-9

_ - __ _ _
MIL-HBEK-23A CHG N O T I C E 3 m 9979970 O L 4 O L 309 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 6-1. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o s u c h that a s i m p l y supported

sandwich panel with i s o t r o p i c c o r e w i l l not buckle under edgewise s h e a r
load.

MIL-HDBK-ZIA CHG NOTICE 3 m q q q q w o O V ~ ~ O F I 245 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
0.8 l.O
3.02
. -
3.04
3.06
Ii
- I i / /
I I I
LEGEND :
- BOTH FACINGS /SO TROPIC
-- BO TH FA CINGS OR THO TRGPIC o.I2
o.I4
F i g u r e 6 - 2 . - - C h a r t f o r determining h / b r a t i o s u c h that a simply supported

__ - -_____ sandwich panel with o r t h o t r o p i c c o r e will not buckle u n d e r edgewise s h e a r
load. (Gcb = O. 4 G ca). .-I,.
~~ . .._-
_/---
~~~~ __
MIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 0 1 4 8 0 2 0 Tb7
b
4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
M 132 681
Figure 6 - 3 . --Chart for determining h / b ratio such that a simply supported

sandwich panel with orthotropic c o r e will not buckle under edgewise shear
load. (Gcb = 2 . 5 G ).
ca

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 6-4. - - C h a r t f o r deterrnining h / b r a t i o s u c h t h a t a s i m p l y supported

I
i sandwich panel with i s o t r o p i c facings and a c o r r u g a t e d c o r e will not
buckle u n d e r edgewise s h e a r load. C o r e c o r r u g a t i o n flutes p a r a l l e l to
edge a.
---I_______
- -.

~-
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
?! 12.2 6R?
Figure 6-5. --Chart for determining h / b ratio such that a simply supported
sandwich panel with isotropic facings and a corrugated core w i l l not
buckle under edgewise s h e a r load. Core corrugation flutes parallel t o
edge b.

-~
MIL-HDBK-23A CHG NOTICE 3 9999970 O348023 776 W
Q)
cn
.rl
3c)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
M
a
cl
F:
.rl
A
U
id
a3
c
(d
cn
k
O
w
OU
a
d
id
3
k
O
>
?
.d
c
'E
k
c)
c,
a
a
k
O
w
c,
k
d
s
c)
I
l
9
I
9 ;
c l r d
k Q )
& 5
M fO A

---
MIL-HDBK-23A CH6 N O T I C E 3 9 9 9 9 9 7 0 0348024 602 M
/C
5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
$ 5
/
ii- LEGE" :
--
60 TU FACINGS /SO TROPX
60TU FACINGS OR TU0TROPE
(FOR D/SS/M/LA R FAC/AfGS SEE 6.3./ II
F i g u r e 6-7.- - K M for sandwich panel with a l l edges s i F p l y s u p p o r t e d , and

isotropic core.
. -
/
i Provided by IHS
-- - - _ _ _
IO
V
tt 3
9
t i
'1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
8 - 1
I 3.02
+b-- 3
!04
.o2
6
l. 04
GC* !08
). 08
--
c 4.-
3.16
?.I6
2
LEGEND :
-50 TH FACINGS IS0 TROPIC
I
- -50 TH FACINGS OR THO TROPIC
(FOR DISSIMIL A R FACINGS SEE 6.3.I )
I I
I I
b
-
U
hf 1 3 L 6 8 5
F i g u r e 6-8. --K M f o r sandwich panel with all edges s i m p l y supported, __

and ~
(Gcb = 0 . 4 G
orthotropic c o r e . c a).

MIL-HDBK-23A CHG N O T I C E 3 M 9999970 0348026 4 8 5 W
tf 3
ti v=-
7TZD
- tIl
b2 U
8 1I 1---- b b - '
2.5 Gc
9/25
3. /25
3.25
3.25
3.50
/. O 0
! 1
O
O 0.2 0.4 O.6 0.8 l
b
-
U
11 1 5 ' t.50
Figure 6-9. --KM f o r sandwich panel with a l l edges s i m p l y supported, and

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
orthotropic c o r e , (Gcb = 2 . 5 G ).
ca

MIL-HDBK-23
W
t * A -
O
i5
20
50
O 0.2 O.4 O.6 O.8 I.

>! 1 3 2 b 8 i
-
b
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 6-10. --K M f o r sandwich panel with all edges simply s u p p o r t e d ,

i s o t r o p i c facings and c o r r u g a t e d c o r e . C o r e c o r r u g a t i o n flutes p a r a l l e l
t o side a.

_. -
/G
V
3
5
8 9.05
3, ' ?
7.50
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 0.2 O.4 O.6 O.8 1.O

>! . &$$
b
-
a
F i g u r e 6-11. --KM f o r sandwich panel with all edges s i m p l y s u p p o r t e d ,
i s o t r o p i c facings and c o r r u g a t e d c o r e . C o r e c o r r u g a t i o n flutes p a r a l l e l
t o s i d e b.

MIL-HBBK-23A CHG N O T I C E 3 N 9999970 0148029 I194 N
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I
F i g u r e 6-12. - - K f o r sandwich panel with a l l edges clamped, i s o t r o p i c

M
facings and i s o t r o p i c c o r e .

____ -__
MIL-HDBK-23A CHG N O T I C E 3 9 7 9 9 9 7 0 O348030 90b
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 0.2 0.4 O.6 O.8 /.O

-
b .
0
!! i ? ? 09:
F i g u r e 6 - 1 3 . --K
f o r sandwich panel with all edges c l a m p e d , i s o t r o p i c
M
facings and o r t h o t r o p i c c o r e . ( G c b = 0 . 4 G ).
ca

MIL-HDBK-23A CHG N O T I C E 3 9999970 OL4803L 4 2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O o.2 O.4 0.6 0.8 /.O

&
-
a
IN 132 691
F i g u r e 6-14. - - K M for sandwich panel with all edges c l a m p e d , i s o t r o p i c

facings and o r t h o t r o p i c c o r e . ( G c b = 2 . 5 G c a).
?
-,
y
_ _ _ ~ _ _ _ _ _
MIL - HDB K - 2 3A
3 0 Dec 1968
CHAPTER 7
DESIGN O F F L A T RECTANGULAR SANDWICH PANELS

UNDER EDGEWISE BENDING MOMENT
Assuming that a design begins with chosen design s t r e s s e s and a given

load t o t r a n s m i t , a flat r e c t a n g u l a r panel of sandwich construction under
edgewise bending moment s h a l l be designed to comply with the four b a s i c
d e s i g n . p r i n c i p l e s s u m m a r i z e d in 1 . 2 of Introduction. T h e s e four conditions
m u s t be met.
O v e r a l l buckling of the sandwich o r dimpling o r wrinkling of the facings

cannot occur without possible t o t a l collapse of t h e panel. Detailed p r o c e d u r e s
giving t h e o r e t i c a l f o r m u l a s and graphs for d e t e r m i n i n g dimensions of the
facings and c o r e t o prevent e l a s t i c buckling, as well as n e c e s s a r y c o r e prop-
e r t i e s , a r e given i n following p a r a g r a p h s . Double f o r m u l a s a r e given, one
f o r m u l a f o r sandwich with i s o t r o p i c facings of different m a t e r i a l s and thick-
n e s s e s and another f o r m u l a f o r sandwich with e a c h i s o t r o p i c facing of the
s a m e m a t e r i a l and thickness. Because edgewise bending m o m e n t c a u s e s
v a r i a t i o n i n facing s t r e s s a c r o s s the panel width, extrapolation to buckling
beyond t h e e l a s t i c r a n g e of facing s t r e s s e s cannot be done by substituting an
effective e l a s t i c modulus, s u c h as a tangent modulus, in the buckling f o r m u l a s .
P r o p e r extrapolation to s t r e s s e s beyond the e l a s t i c r a n g e m u s t consider the
v a r i a t i o n of effective e l a s t i c modulus a c r o s s the panel width a s s o c i a t e d with
the s t r e s s variation. T h e information given h e r e is thus s t r i c t l y applicable
only to buckling at facing s t r e s s e s within the e l a s t i c range. Facing modulus
of e l a s t i c i t y , E, and s t r e s s v a l u e s , F , s h a l l be c o m p r e s s i o n values at the
C
conditions of use; that i s , i f application is at elevated t e m p e r a t u r e , then
facing p r o p e r t i e s a t elevated t e m p e r a t u r e s h a l l be used i n design.
Edgewise bending moment applied to a s i m p l y supported, flat r e c t a n g u l a r

sandwich panel produces the loading shown i n the s k e t c h i n f i g u r e 7-1. Half
of the panel i s i n edgewise tension, which is a s t a b l e condition, but the other
half is i n edgewise c o m p r e s s i o n . The edge c o m p r e s s i o n load, varying f r o m
z e r o at t h e n e u t r a l axis t o a m a x i m u m value, N, at the panel edge, can p r o -
duc e buckling.
i
7-1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

1
MIC-HBBK-23A C V G N O T I C E 3 H 9999970 0348033 615
I T h e value of N at the panel edge is d e t e r m i n e d by the f o r m u l a
N = -6M (7:l)
b2
w h e r e N is load p e r unit edge width, M is edgewise bending moment, and b i s

panel width.
T h e f o r m u l a s f o r buckling i n edgewise bending a r e similar to those f o r

edgewise c o m p r e s s i o n buckling, but the c r i t i c a l edge load, N , is higher
cr
f o r edgewise bending.
Facing stresses are r e l a t e d t o t h e edge load by t h e equations:
t l F c l t t2Fc2= N (for unequal facings) (7:2)
t=-
N
. (for equal facings) (7:Za)
2F
C
w h e r e t is facing t h i c k n e s s ; F is chosen design facing c o m p r e s s i v e s t r e s s ;

C
N is design c o m p r e s s i o n load p e r unit length of panel edge; and 1 , 2 a r e s u b - _-
s c r i p t s denoting facings 1 and 2.
In d e t e r m i n i n g t h i c k n e s s e s of facings for sandwich with facings of differ-

ent m a t e r i a l s , equation ( 7 : 2 ) m u s t be s a t i s f i e d , but a l s o the s t r e s s e s F
cl
and F m u s t be chosen s o that Fc l / E 1 = F / E ( w h e r e E is facing modulus
c2 c2 2
of e l a s t i c i t y ) , thus avoiding o v e r s t r e s s i n g of e i t h e r facing. F o r example, i f
facing 1 is of a m a t e r i a l s u c h that the r a t i o Fc l / E 1 = O. 005 and facing 2 is of
a m a t e r i a l s u c h that the r a t i o Fc 2 / E 2 = 0 . 0 0 2 , the designs m u s t be b a s e d on
a r a t i o of O. 002; o t h e r w i s e facing 2 w i l l be o v e r s t r e s s e d . In o r d e r to a c c o m -
p l i s h t h i s , the chosen d e s i g n s t r e s s e s for facing 1 m u s t be lowered. F o r
m a n y combinations of facing m a t e r i a l s , it w i l l be found advantageous to choose
t h i c k n e s s e s s u c h that E l t l = EZt2. If the c o r e can support edge load, N should
be r e p l a c e d by ( N - F ct c).
7-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- _--___I__-
-
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0 3 4 8 0 3 4 5 5 1
7. 3 DETERMINING CORE THICKNESS

T h i s section gives p r o c e d u r e s for determining c o r e thickness and c o r e

s h e a r modulus s o that o v e r a l l buckling of the sandwich panel w i l l not occur
(refs. 7-1 and 7 - 2 ) .
The load per unit panel width at the panel edge at which buckling of a
2
TT
sandwich panel will o c c u r is given by the t h e o r e t i c a l formula: N = K - D,
cr
b2
w h e r e D is the sandwich bending s t i f f n e s s . This f o r m u l a solved for the f a c -
ing s t r e s s becomes :
2 E
F 2K
=TT E I t 1E2t 2 192
(7: 3)
cl, 2
( E l t i + E2t2)
2
where E is modulus of e l a s t i c i t y of facing; A = 1 - p ; p is P o i s s o n ' s r a t i o
of facings ( i n f o r m u l a (7:3) i t is a s s u m e d that p = p l = p2); h is distance
between facing c e n t r o i d s ; b is length of loaded panel edge; K = K + KM;
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F
K is a t h e o r e t i c a l coefficient dependent on facing stiffness and panel aspect
F
r a t i o ; and K is a t h e o r e t i c a l coefficient dependent on sandwich bending and
M
s h e a r rigidities and panel aspect r a t i o .
Solving equations (7:3) and (7:3a) f o r h / b gives:
--, r--- (7:4)

v EltlEZtZ/
h
-=- (for equal facings) (7:4a)
.-fi
T h e r e f o r e , if K is known, equation (7:4) o r (7:4a) can be solved d i r e c t l y to
eventually obtain h because a l l other quantities a r e known. After h i s
obtained, the c o r e t h i c k n e s s , t , is computed f r o m the formulas:
C
7-3

t t t2
1
t = h - (7:5)
C 2
t
C
=h -t (for equal facings) (7:5a)
A s a f i r s t approximation, i t w i l l be a s s u m e d that K = O , hence K =

KM' F
Values of K depend upon the bending and s h e a r r i g i d i t i e s of t h e sandwich a s
M .-,
L
incorporatedinthe parameter V = -
TI which c a n be written a s :
b2 U
2
r t E t E t
c 1 1 2 2
v= 7 (7: 6)
b L l ( E l t l t E2t2)Gc
2
r t Et
C
V = (for equal facings) (7: 6a)
2b2XG
C
where U i s sandwich s h e a r s t i f f n e s s ; G i s the c o r e s h e a r modulus a s s o c i a t e d __

C
with the a x e s p a r a l l e l to the d i r e c t i o n of loading ( a l s o p a r a l l e l to panel side
of length a) and perpendicular to the plane of the panel. A s values of c o r e
s h e a r modulus d e c r e a s e , values of V i n c r e a s e and values of K gradually
M
d e c r e a s e . F o r sandwich with c o r r u g a t e d c o r e having corrugation flutes
p a r a l l e l to the d i r e c t i o n of loading, the p a r a m e t e r V i s r e p l a c e d by the
par ameter:
2
i r t E t E t
c 1 1 2 2
(7:7)
2
TI t Et
C
W = (for equal facings) (7: 7).
2
2b h G c b
where G is the c o r e s h e a r modulus a s s o c i a t e d with the axes perpendicular

cb
t o d i r e c t i o n of loading ( p a r a l l e l t o panel s i d e of length b) and perpendicular
to the plane of the panel.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__ --
= 7799970
- -
MIL-HDBK-23A CHG NOTICE 3 0348036 3 2 4
7. 3. 1 Determination of Minimum Values of h
A m i n i m u m value of h r e q u i r e d w i l l be d e t e r m i n e d by a s s u m i n g V = O o r
W = O f o r a f i r s t approximation. T h e value of h is m i n i m u m because V = O
o r W = O only i f t h e c o r e s h e a r modulus is infinite; f o r any actual c o r e , the
s h e a r modulus is not infinite, hence a t h i c k e r c o r e m u s t be used. The
m.inimum value of h m a y be found using V = O o r W = O i n any of t h e c h a r t s in
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f i g u r e 7-1 through 7-4. T h e s e c h a r t s apply t o simply supported sandwich

panels having i s o t r o p i c facings and i s o t r o p i c , o r t h o t r o p i c , o r c o r r u g a t e d
cores.
P a r a m e t e r s needed for u s e of t h e c h a r t s are:
1. Panel aspect ratio a / b o r b / a
XFcl, 2
2. . F a c i n g p r o p e r t i e s
3. Ratio of E t / E l t l
2 2
7. 3. 2 Determination of Actual Values of h
Since actual c o r e s h e a r modulus values a r e not v e r y l a r g e , a value of h

somewhat g r e a t e r than that d e t e r m i n e d by a s s u m i n g V = O o r W = O m u s t be
used. C h a r t s for d e t e r m i n i n g h for sandwich with all edges s i m p l y supported
a r e shown i n f i g u r e s 7-1, 7 - 2 , 7 - 3 , and 7-4. The f i g u r e s a r e e n t e r e d with
values of the panel a s p e c t r a t i o and values of V as computed by equation (7:6)
o r (7:6a) o r values of W as computed by equation (7:7) o r (7:7a). F i g u r e 7-1
applies t o sandwich with i s o t r o p i c c o r e s f o r which the c o r e s h e a r modulus
perpendicular t o t h e d i r e c t i o n of loading is equal t o t h e c o r e s h e a r modulus
p a r a l l e l t o the d i r e c t i o n of loading. F i g u r e 7 - 2 applies t o sandwich with
honeycomb c o r e s for which the c o r e s h e a r modulus perpendicular to the
d i r e c t i o n of loading is equal t o 0 . 4 0 t i m e s the c o r e s h e a r modulus p a r a l l e l
t o the d i r e c t i o n of loading. F i g u r e 7 - 3 applies t o sandwich with honeycomb
c o r e f o r which the c o r e s h e a r modulus perpendicular t o the d i r e c t i o n of load-
ing is 2.50 t i m e s the c o r e s h e a r modulus p a r a l l e l t o t h e d i r e c t i o n of loading.
Note: F o r honeycomb c o r e s with c o r e ribbons p a r a l l e l to d i r e c t i o n of

loading, C = GTL and the s h e a r modulus perpendicular t o loading is G
C TW'
For honeycomb c o r e s with c o r e ribbons perpendicular t o d i r e c t i o n of load-
ing, G
C %W
--and t h e s h e a r modulus perpendicular t o loading is G
T L'
7 -5

____
NIL-HDBK-23A CHG N O T I C E 3 9999970 0348037 260 W
F i g u r e 7 - 4 applies to sandwich with c o r r u g a t e d c o r e having the c o r e flutes

p a r a l l e l t o the d i r e c t i o n of loading.
In using f i g u r e s 7 - 1 , 7-2, 7 - 3 , and 7-4, it is n e c e s s a r y t o iterate b e c a u s e

V and W are d i r e c t l y proportional t o t h e c o r e thickness t A s a n aid t o
C
.
finally d e t e r m i n i n g t and G , figure 7-5 p r e s e n t s a number of lines r e p r e s e n t -
C C
i n g V f o r v a r i o u s values of G with V ranging f r o m O. O1 to 2 and G ranging
C C
from 1 , 0 0 0 t o 1 , 0 0 0 , 0 0 0 pounds p e r s q u a r e inch. T h e following p r o c e d u r e is
suggested:
1. D e t e r m i n e a c o r e thickness t f r o m f i g u r e 7-1, 7 - 2 , 7-3, o r 7-4 using

C
a value of O. O1 f o r V o r W.
2. Compute t h e constant r e l a t i n g V o r W to G
C
.
(for equal f a c i n g s ) = V G o r WG
C C
3. With t h i s constant, e n t e r figure 7-5 and d e t e r m i n e n e c e s s a r y G

C
. -
4. If the s h e a r modulus is outside the r a n g e of values f o r m a t e r i a l s a v a i l -
a b l e , s l i d e up the a p p r o p r i a t e line of f i g u r e 7-5 and pick a new value of V o r
W , f o r a r e a s o n a b l e value of c o r e s h e a r modulus.
5. R e e n t e r figure 7-1, 7-2, 7 - 3 , o r 7-4 with the new value of V o r W

and r e p e a t previous s t e p s 1 , 2, and 3.
7 . 3 . 3 Checking P r o c e d u r e f o r Determining
Buckling S t r e s s , F
cr
T h e design s h a l l be checked by using the g r a p h s of f i g u r e s 7-6 t o 7-9 t o

d e t e r m i n e v a l u e s of K f o r u s e i n evaluating K = K t KM t o substitute into
M F
f o r m u l a (7:3) o r ( 7 : 3 a ) t o compute actual buckling s t r e s s , F
cr
The f i g u r e s .
apply t o sandwich panels with edges s i m p l y supported and
with i s o t r o p i c o r c e r t a i n o r t h o t r o p i c c o r e s ( s e e 7. 3. 2).
7-6
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

F o r e a c h value of t h e p a r a m e t e r V o r W , t h e r e is a cusped c u r v e giving
v a l u e s of K f o r v a r i o u s v a l u e s of t h e r a t i o a / b o r b / a . T h e s e c u s p s a r e
M
indicated by dotted l i n e s f o r t h e top c u r v e i n e a c h figure. T h e c u s p s s h o w
t h e sandwich panel buckling coefficients calculated for different values of n ,
t h e n u m b e r of half waves into which the panel buckles. Only t h e portions of
e a c h c u s p e d c u r v e f o r which K is a m i n i m u m a r e shown. Envelope c u r v e s
M
i n d i c a t e v a l u e s of K f o r u s e i n design.
M
Values of K s h a l l be d e t e r m i n e d f r o m t h e formula:
F
3 3
(E t t E t ) ( E l t l t E t )
- 1 1 2 2 2 2
(7:8)
KF - 7
KMO
12E t E 2 t 2hL
L
K F =2 KMO
3h
I where K
MO
= KM when V = O o r W = O and thus cah be obtained f r o m the
>
g r a p h s of f i g u r e s 7-6 to 7-9. F o r panels with a / b r a t i o s = 0 . 4 , it can be
a s s u m e d t h a t K = O. T h e n K s h a l l be computed as K + KM - KM and -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F F
equation (7:3) o r (7:3a) solved f o r F
cr
.
If t h e c h a r t s do not apply b e c a u s e r a t i o s of c o r e s h e a r moduli a r e f a r
different f r o m what is given on t h e c h a r t s , o r i t is d e s i r e d t o check by a
m o r e a c c u r a t e a n a l y s i s , t h e f o r m u l a s given i n r e f e r e n c e s i - 1 and 7 - 2 s h a l l
be used.
( 7 - 1) HARRIS, LEONARD A . , and AUELMANN, RICHARD R.

1960. Stability of F l a t , Simply Supported C o r r u g a t e d - C o r e Sandwich
Plates Under Combined Loads. J o u r n a l of the A e r o /Space
S c i e n c e s , Vol. 27, No. 7 , p. 525-534. July.
I ( 7 - 2 ) KIMEL, W. R.
1956. E l a s t i c Buckling of a Simply Supported Rectangular Safidwicli
P a n e l Subjected t o Combined Edgewise Bending and C o m p r e s s i o n .
U.S. F o r e s t P r o d . Lab. Rep. 1857A.
7-7

- -. -
I
~ _ _ - --
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6

-
U
&
F i g u r e 7 - 1 . - - C h a r t f o r determining h / b r a t i o s u c h that a simply

supported sandwich panel with i s o t r o p i c facings and i s o t r o p i c c o r e .
w i l l not buckle e l a s t i c a l l y u n d e r edgewise bending load. (Gcb = G c a ).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9999970 O148040 855
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
H 132 951
F i g u r e 7 - 2 . - - C h a r t f o r d e t e r m i n i n g h / b r a t i o s u c h t h a t a simply
supported sandwich panel with i s o t r o p i c facings and o r t h o t r o p i c
c o r e will not buckle e l a s t i c a l l y u n d e r edgewise - bending- load.
(Gcb = 0 . 4 Gc,).

____
MIL-HDBK-23A C H G N O T I C E 3 m 9 9 7 7 9 7 0 0148041 791 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
~~
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O

-
U b
-
b a
M 132 95'
F i g u r e 7 - 3 . --Chart f o r determining h / b ratio such that a simply
s u p p o r t e d sandwich panel w i t h i s o t r o p i c f a c i n g s and o r t h o t r o p i c
c o r e w i l l not b u c k l e e l a s t i c a l l y u n d e r edgewise bending load.
(Gcb = 2 . 5 G ).
ca

MIL-HBBK-23A CHG N O T I C E 3 9999970 0348042 628 W
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O

-U h
b 4
o.01
%O2
0.03
3.04
O.05
0.06
3.07
O.08
n 1 3 2 948 F i g u r e 7 - 4 . - - C h a r t for determining h / b r a t i o s u c h that a simply

supported sandwich panel with i s o t r o p i c facings and a c o r r u g a t e d
c o r e will not buckle e l a s t i c a l l y u n d e r edgewise bending load. C o r e
c o r r u g a t i o n flutes p a r a l l e l to s i d e a.
.--

v OR w
c
O
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
8
$a
o
o
ni
O
Y
rn
pi
P
a
$
I-.
o
Y
5'
(D
a
09

- - _____ - ._
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 O348044 4 T 0
40
36
32
28
24
3 20
/6
/2
1
8
FOR V Z 0.2/5 KM = / . 8 8 6 / V
I
O
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
U
- b
-
b u
M 132 951
F i g u r e 7 - 6 . --KM f o r simply supported sandwich panel with i s o t r o p i c

core. (Gcb = G ).
ca
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~-
=
~-
NIL-HbBY-23A CHG N O T I C E 3 E 7 9 9 9 9 7 0 0148045 337
4c
36
Gt w i
32 l I
l
v=o
I
I I Y
28
24
$ 2G
_--
16
/2
8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
4
I I I FOR V ? 0.4 K~=/.886/V I I
O
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
-
U b
-
b U
M 132 952
F i g u r e 7 - 7 . --KM f o r s i m p l y s u p p o r t e d sandwich panel with

_-
orthotropic core. (Gcb = O . 4 G ).
ca
I-
-__ _____--

MIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 0 3 4 8 0 4 6 2 7 3 W
4L
36
Gc *
32
28
24 1 \ 1 I I I I I I
I
I
2 20
16
/2
O
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O

-
O -
b
b U
M 132 9 5 0
F i g u r e 7 - 8 . - - K M f o r simply supported sandwich panel with

orthotropic c o r e . (Gcb = 2.5 G ).
ca

[IL-HDBK-23A CHG N O T I C E 3 9 7 7 9 9 7 0 OL48047 L O T
/-
O 0.2 0.4 0.6 0.8 /.O 0.8 0.6 0.4 0.2 O
F i g u r e 7 - 9 . --KM f o r s i m p l y supported sandmrich panel with c o r r u g a t e d

core. C o r e c o r r u g a t i o n flutes p a r a l l e l to side a .
----------
,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 W 9999970 O L 4 O 4 O46 M
MIL -HDBK- 23A

3 0 Dec 1968
CHAPTER 8
DESIGN O F FLAT RECTANGULAR SANDWICH PANELS
I 8. 1 BASIC PRINCIPLES

design load t o t r a n s m i t , a flat r e c t a n g u l a r panel of sandwich construction under
edgewise loads with o r without loads d i r e c t e d n o r m a l to the plane of the s a n d -
wich s h a l l be designed to comply with the four basic d e s i g n principles s u m -
m a r i z e d in 1. 2 of the Introduction.
F a c i n g s t r e s s e s s h a l l be d e t e r m i n e d for e a c h load applied s e p a r a t e l y

( s e e a p p r o p r i a t e C h a p t e r s ) and the effects of combining the loads and s t r e s s e s
s h a l l be a s s e s s e d by a p p r o p r i a t e i n t e r a c t i o n f o r m u l a s for the facing m a t e r i a l s
a s given in r e f e r e n c e s (8-8) and (8-9) wherein design values of t h e s e s t r e s s e s
a r e established.
O v e r a l l buckling of the sandwich o r dimpling o r wrinkling of the facings

cannot o c c u r without possible t o t a l collapse of the panel. L o c a l f a i l u r e by
wrinkling of the facings under loads other than uniaxial c o m p r e s s i o n a r e not
given and i t is n e c e s s a r y to d e t e r m i n e this behavior of the sandwich by t e s t -
i n g s m a l l s p e c i m e n s if e s t i m a t e s based on i n f o r m a t i o n given i n Chapter 3
show that f a i l u r e by wrinkling of facings could be expected. Dimpling of
facings under combined loads is not given; however, the information given
i n Chapter 4 c a n be combined with i n t e r a c t i o n f o r m u l a s for buckling of the
individual facing s h e e t s as a r e given i n r e f e r e n c e s (8-1) and (8-8) to obtain
s o m e e s t i m a t e s that c a n be confirmed by t e s t s of s m a l l s p e c i m e n s .
O v e r a l l buckling of sandwich panels under combined loads is given by

interaction f o r m u l a s i n t e r m s of the r a t i o s , R , w h e r e i n R denotes the r a t i o
of the applied s t r e s s o r load under combined loading to the buckling s t r e s s
o r load u n d e r s e p a r a t e loading (R = N / N ). Appropriate s u b s c r i p t s a r e
cr
given to R t o denote s t r e s s o r load and direction.
8-1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I Provided by IHS
-. . ~~ . . Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard
MIL-HDBK-23A CHG N O T I C E 3 M 7 9 7 7 7 7 0 0148049 T A 2 M
8.2 BIAXIAL COMPRESSION
O v e r a l l buckling of sandwich panels under biaxial c o m p r e s s i o n can be

e s t i m a t e d by the i n t e r a c t i o n f o r m u l a
R + R = I (8:1)
cx CY
T h i s f o r m u l a is c o r r e c t f o r s q u a r e , i s o t r o p i c sandwich panels f o r which

V S O . It c a n be exceedingly conservative f o r long panels and f o r panels with
V >>O. F o r m o r e a c c u r a t e a n a l y s e s including sandwich with c o r r u g a t e d c o r e
consult r e f e r e n c e s (8-1), (8-2), (8-4), (8-5), and (8-7).
8.3 BENDING AND COMPRESSION
O v e r a l l buckling of sandwich panels under edgewise bending and c o m p r e s -

s i o n applied.at t h e panel ends c a n be e s t i m a t e d by the i n t e r a c t i o n f o r m u l a
312
R t (RBx) = 1 (8:2)
cx
Approximate values which m a y be conservative can be obtained f r o m

f o r m u l a (8:2). F o r more a c c u r a t e a n a l y s e s including sandwich-with c o r r u g a t e d
c o r e s e e r e f e r e n c e s (8-2),(8-3), and (8-7).
8.4 COMPRESSION AND SHEAR
O v e r a l l buckling of sandwich panels under edgewise c o m p r e s s i o n and

s h e a r c a n be e s t i m a t e d by the i n t e r a c t i o n f o r m u l a
2
R c t (Rs) = 1 (8:3) 1
R e f e r e n c e s ( 8 - i ! ) , (8-5), and (8-7) contain m o r e complete information.
8 . 5 BENDING AND SHEAR
O v e r a l l buckling of sandwich panels under edgewise bending and s h e a r

can be c l o s e l y approximated by the i n t e r a c t i o n f o r m u l a
8-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~ _____ _______ ~-~- ~
MIL-HBBK-23A C H G N O T I C E 3 E 9 9 9 9 9 7 0 0348050 7T4
(8:4)
Details of the analysis leading to t h e s e i n t e r a c t i o n c u r v e s a r e given i n

r e f e r e n c e s ( 8 - 2 ) and ( 8 - 3 ) .
8 . 6 EDGE LOADS COMBINED WITH NORMAL LOADS
The combination of edge loads with loads d i r e c t e d n o r m a l to the plane of

a sandwich panel can greatly magnify deflections and s t r e s s e s due t o the
n o r m a l load only (design information for panels under n o r m a l load only is
given i n Chapter 9). The deflections and s t r e s s e s under combined loads can
be closely approximated by the f o r m u l a
$0
+= (8:5)
N
1 --
N
cr
w h e r e $ is deflection o r s t r e s s due to edgewise load combined with n o r m a l

load; $ is deflection o r s t r e s s due to n o r m a l load only; N i s edgewise load-
O
ing (single o r combined); and N is o v e r a l l edgewise buckling load (single
cr
o r combined). Details concerning f o r m u l a (8:5) a r e given i n r e f e r e n c e s (8-6)
and ( 8 -7).
8-3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

--__-_______-
.-.
GERARD, GEORGE and BECKER, HERBERT

1957. Handbook of S t r u c t u r a l Stability, P a r t I- -Buckling of Flat
P l a t e s . NACA Tech. Note 3781.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
HARRIS, LEONARD A. and AUELMANN, RICHARD R.

1960. Stability of F l a t , Simply Supported C o r r u g a t e d C o r e Sandwich
Rectangular Plates Under Combined Loadings. J o u r n a l of
Aero/space S c i e n c e s , Vol. 27, No. 7, p. 525-534.
KIMEL, W. R.
1956. E l a s t i c Buckling of a Simply Supported Rectangular Sandwich
P a n e l Subjected t o Combined Edgewise Bending, C o m p r e s s i o n ,
and S h e a r . U.S. F o r e s t P r o d . Lab. Rep. 1859.
NOEL, ROBERT G.
1952. E l a s t i c Stability of Simply Supported Flat Rectangular P l a t e s
.
Under C r i t i c a l Combinations of Longitudinal Bending,
Longitudinal C o m p r e s s i o n , and L a t e r al C o m p r e s sion. J o u r n a l
of t h e Aeronautical S c i e n c e s , Vol. 19, No. 12, 829-834.
NORRIS, CHARLES B. and KOMMERS, WILLIAM J.
1952. C r i t i c a l L o a d s of a R e c t a n g u l a r , F l a t Sandwich P a n e l Sub- --
j e c t e d t o Two D i r e c t L o a d s Combined With a S h e a r Load.
U.S. F o r e s t Prod. Lab. Rep. 1833.
NORRIS, CHARLES B. and KOMMERS, WILLIAM J.
1953. S t r e s s e s Within a R e c t a n g u l a r , F l a t Sandwich P a n e l Subjected
t o a Uniformly D i s t r i b u t e d N o r m a l Load and Edgewise, D i r e c t ,
and S h e a r Loads. U.S. F o r e s t P r o d . Lab. Rep, 1838.
PLANTEMA, FREDERICK J.
1966. Sandwich Construction. J o h n Wiley & Sons, Inc.
U. S. DEPARTMENT O F DEFENSE
Current Plastics f o r Flight Vehicles: P a r t I , Reinforced P l a s t i c s .
Available f r o m U. S . Cov. p r i n t i n g Office, Washington, D. C .

S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U. S . Cov.
P r i n t i n g O f f i c e , Washington, D. C.
8-4

I?. = ----- .
flIL-HDBK-23A CHG NOTICE 3 9999770 0248052 577
CHAPTER 9
DESIGN O F FLAT SANDWICH PANELS
UNDER UNIFORMLY DISTRIBUTED NORMAL LOAD
Assuniing t h a t a design begins with chosen design s t r e s s e s and

deflections and a given load to t r a n s m i t , a flat r e c t a n g u l a r o r c i r c u l a r
panel of sandwich construction u n d e r uniformly distributed n o r m a l load
I
s h a l l be designed to comply with the f o u r basic design p r i n c i p l e s s u m m a -
i r i z e d i n 1. 2 of the Introduction.
Detailed p r o c e d u r e s giving t h e o r e t i c a l f o r m u l a s and g r a p h s f o r d e t e r -

mining dimensions of the facings and c o r e , a s w e l l as n e c e s s a r y c o r e prop-
erties, f o r s i m p l y supported panels a r e given. in t h e following p a r a g r a p h s .
Double f o r m u l a s a r e given, one f o r m u l a f o r sandwich with i s o t r o p i c facings
of different materials and t h i c k n e s s e s and another f o r m u l a f o r sandwich witn
e a c h i s o t r o p i c facing of the s a m e material and thickness. F a c i n g modTAli of
elasticity, and stress v a l u e s , s h a l l be c o m p r e s s i o n or teL.5iGZ-i
2, =1,2,
v a l u e s at the condition of u s e ; t h a t i s , if application is at elevated t e n p e r a -
t u r e , then facing p r o p e r t i e s at elevated t e m p e r a t u r e shall be used in d e s i g n .
F o r many combinations of facing m a t e r i a l s it w i l l be found avantageous t o
choose t h i c k n e s s e s s u c h that E t = E2t2. The following p r o c e d u r e s a r e
I l
r e s t r i c t e d to l i n e a r e l a s t i c behavior.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

M I L - H D B K - ~ ~ A NIL-HDBK-23A
9 March 1972
C H G N O T I C E 3 W 9 7 9 9 9 7 0 0148053 403 -
A N D C O R E S H E A R MODULUS F O R SiMPLY SL7P2V12YE:3
F L A T R E C T A N G U L A R PAXNELS
T h i s s e c t i o n gives p r o c e d u r e s f o r determining sandLvIch facing an8

c o r e t h i c k n e s s e s and c o r e s h e a r modulus s o that chosen d e s i g n facing
s t r e s s e s and allowable pariel deflections w i l l not be exceeded ( r e i . 9 - 2 ,
9 - 3 ) . The facing s t r e s s e s , produced by bending m o m e n t , a r c m a x i m u r :
at the c e n t e r of a s i m p l y supported panel under u n i f o r m l y distributed
n o r m a l load. If r e s t r a i n t e x i s t s a t panel e d g e s , a redistribution of s t r e s s e s
m a y c a u s e higher s t r e s s e s n e a r panel edges. The ;?rocediLres given a p p l y
only t o panels with simply supported edges. Because facing s t r e s s e s z r e
caused by bending m o m e n t , they depend not only upon facirg t h i c k n e s s
- . .
but a l s o upon the d i s t a n c e the facings a r e s p a c e a , hence ccire rbici<;-ic-ss.
P a n e l stiffness, hence deflection, i s a l s o dependent upon facing and cGre
thickne s s.
If the panel is designed so that facing s t r e s s e s a r e a t chosen iesigrL

l e v e l s , t h e panel deflection m a y b e l a r g e r than allowable, i s w h i c h c a s e
the c o r e o r facings m u s t be thickened and the d e s i g n facing s t r e s s !owered
in o r d e r to m e e t deflection r e q u i r e m e n t s . A solution is p r e s e n t e d in the
f o r m of c h a r t s with which, by i t e r a t i v e p r o c e s s , the facing and c a r e thick-
n e s s e s and c o r e s h e a r modulus c a n be d e t e r m i n e d ,
The a v e r a g e facing s t r e s s , F ( s t r e s s a t facing <.efi:rJir!i. ir. the

1
b direction- i s given by the t h e o r e t i c a l formLila:
- 2
2
(for equal f a c i n g s )
= K 2 ht
-For sandwich with o r t h o t r o p i c c o r e s having g r e a t e r rigidity In the a

d i r e c t i o n than in the b d i r e c t i o n , the facing s t r e s s may b e g r e a t e r i n ??;e
a d i r e c t i o n than the b d i r e c t i o n , f o r panels n e a r l y sqiiare ( b / a > O. 4 j ,
and t h i s s t r e s s is dependent upon K given in f i g u r e s 9 - 1 6 , Ct-l, an^
2
9-18.
9-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

No reproduction or networking permitted without
a license from IHS Not for Resale, 09/27/2006 07:13:23 MDT
NIL-HDBK-Z~A CHG N O T I C E 3 m 9999970 0148054 3 4 T = -
y----.-.-..
4
:-L,fip.-L
I 'LL
a.
- 3,
- --- --. - - 7-
;
I
1IC-LL-L
w h e r e p is the intensity of t h e d i s t r i b u t e d load; ?u i a L I ; ~ p a n c i LX ;. ~ -t k i;. .;

t h e d i s t a n c e between facing ceritroicls; i is iaL.i-ng~ ~ l l ~ ' k J > < k Sl .. L.):.:i
.: .i .-\-
gubBcrpL8 denoting facings- 1 and 2 ; :~nil I.; ius n t i ~ ( - , ~ ; L- i~' i\i ,i L . , b c . . . . i , . L . - : . :
&!
dependent on panel a s p e c t r a t i o , and sandwich bending Lrnri sheai- : - i h , r . i ~ - . : s ~ . ~ .

i f the c o r e i s i s o t r o p i c ( s h e a r moduli alike in the two p r l n c t p a i direc-ic):-tsj.
K 2 values depend only.upon panel a s p e c t r a t i o . The v a i u e s of Ii, f o r s a n s -
I-
wich with o r t h o t r o p i c c o r e a r e dependent not only on panel a s p e c t r a t i o h t

a l s o upon sandwich bending and s h e a r r i g i d i t i e s a s i n c o r p o r a t e d in t h e
2
parameter V =
T D
- which c a n be w r i t t e n as:
b2U
2
tcE1tlE2t2
V =
2
Ab G ( E I t l t E 2 t 2 )
C
i
r L t Et
C
V = (for equal f d c i n g s )
2
2Xb G
C
w h e r e U i s sandwich s h e a r s t i f f n e s s , E is modulus of e l a s t i c i t y of f a c i s z :
- 2
A = 1 ,u ; p is P o i s s o n ' s r a t i o of facings ( i n f o r m u l a 9:2 it is a s s u r r e ? thai
p F p 1 = p ); and G i s t h e c o r e s h e a r modulus a s s o c i a t e d with a x e s paralie!
2 C
t o panel s i d e of length a and p e r p e n d i c u l a r t o t h e plane of the pailei. T > e
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
c o r e s h e a r modulus a s s o c i a t e d with a x e s p a r a l l e l t o pane; s i d e of width b

and p e r p e n d i c u l a r to t h e plane of t h e panel is denoter! by (RG,.). F o r s a n d -
wich with c o r r u g a t e d c o r e h a v i n g c o r r u g a t i o n f l u t e s parai!ei to panel s i r i r .
of length a the parameter V is r e p l a c e d by the p a r a m e t e r
2
T t E t E t
c 1 1 2 2 ( 9 i..!
W = 3 7
XbLG (Eltl t EZt2)

cb
9-3

9 March 1972
2
T r t t t .
C
w= 2
(for equal f a c i n g s ) jc):5,;
2kb Gcb
where G is the c o r e s h e a r modulus a s s o c i a t e d with the a x e s p e r p e n e i c -

cb
u l a r to the d i r e c t i o n of the c o r r u g a t i o n flutes ( p a r a l l e l t o panel s i d e of
length b) and p e r p e n d i c u l a r to the plane of the panel.
Solving equations (9:l) and ( 9 : l a ) f o r h gives -

b
-h --
b
( 9 :4a)
A c h a r t f o r solving f o r m u l a s (9:4) and (9:4a) graphicall>- is given i n

f i g u r e s 9-1, 9 - 2 , and 9 - 3 . The f o r m u l a s and c h a r t s include the r a t i o t/k,
which is usually unknown,' but by i t e r a t i o n s a t i s f a c t o r y r a t i o s of t / h and
' h / b c a n be found,
The deflection, 6 , of the panel c e n t e r is given by the t h e o r e t i c a l

formula :
K1
6 =- (9 :5 1
K2 E h
6 = 2-. -.XE F -
b2
h
(for equal f a c i n g s ) ( 9 :5a)
K2
9 -4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Ai
Provided by IHS
where K i s a coefficient dependent upon panel aspecx r a t i o a n t :-e T-,,..c ,i
1
V o r W and in sandwich with c o r r u g a t e d c o r e o n t k e raEic hea-ec.:: r::< s x i -
wich bending s t i f f n e s s p a r a l l e l and p e r p e n d i c u k r to t n i c : r ~ g ~ ~ f i f.x.rds.
.;
h .
Solving equations (9:5) and (9:5a) f o r -
b
gives
(9 :6 j
-h - (for e q u a l f a c i n g s ) (9:aj
b-
C h a r t s f o r solving f o r m u l a s (9:6) and (9:6a) a r e given ii, fig-res 5-4,

9-5, 9-6, 9-7, and 9-8. U s e of the eqiiations and c h a r t s beyozd :/i; = O. 5
is not recommended.
9.2. 1 U s e of Design C h a r t s
The sandwich m u s t b e designed by i t e r a t i v e p r o c e d u r e s and the c h a r t s

enable r a p i d determination of the v a r i o u s quantities sought. F o r pane! witk
i s o t r o p i c and honeycomb c o r e the c h a r t s w e r e derived f o r a Poisson's
ratio of the facings of O. 3 , and can b e u s e d with s r L a I l e r r o r f G r f a c i n g s
having other v a l u e s of P o i s s o n ' s ratio. F o r pancls with curri:gate<! c G r e
'
they w e r e derived for a P o i s s o n ' s r a t i o of t h e facings of O. 25.
As a first approximation, it w i l l be a s s i a n e d that V o r W = If the O.

design is controlled by facing s t r e s s c r i t e r i a , a s m a y be d e t e r m i n e d , t h i s
assumption w i l l lead to a n exact value of h if the c o r e is i s o t r o p i c ; t o a IX~:-L-
i m u m value of h if t h e c o r e is o r t h o t r o p i c with a g r e a t e r c o r e s h e a r I X G ~ ~ - L S
a c r o s s t h e panel width than lengthwise: and to too l a r g e a value of h if t h e
c o r e is o r t h o t r o p i c with a smaller c o r e s h e a r modulus a c r o s s the panel
width than lengthwise. If t h e design is controlled by deflection requireE>ents,
the a s s u m p t i o n t h a t V = O w i l l produce a m i n i m u m value o i h. The value of
h i s m i n i m u m b e c a u s e V = O i f t h e c o r e s h e a r modulus i s infinite. For any
actual core, the s h e a r modulus is not infinite; hence a t h i c k e r c o r e m u s t
be used.
9-5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_ _ ___
MU-H13BK-23,
NIL-HDRK-23A CHG N O T I C E 3 = 999q970 0148057 059
9 March 1972
The following p r o c e d u r e is suggested:
parameters b/a and

t,
F
1,2
-
r>
, using the c u r v e for V o r W = O. Assunie a
.
.
value'*for
e
-
h
'-3
and d e t e r m i n e h/b. Compute h and t Modify r a t i o

1.2'
-if n e c e s s a r y and d e t e r m i n e m o r e suitable values f o r h and t
bl, 2
h . 1,2'
Check stress i n a d i r e c t i o n as per footnote 1.
(2) Enter figure 9-4, 9-7, o r 9-8 with d e s i r e d v a l u e s f o r the p a r a m -
eters b/a, -
E2t2 F2
, using t h e c u r v e for V o r W = U. Assume a
E l t l ' - E2
value o 6/h a n d d e t e r m i n e h/b. Compute h and 6. Modify r a t i o / h i f
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
n e c e s s a r y and d e t e r m i n e m o r e h i t a b l e v a l u e s f o r h and 6.
(3) Repea s t e p s (1) and (Z), using lower chosen design facing
stresses, until h d e t e r m i n e d by s t e p ( 2 ) is e q u a l t o , o r a bit less than,
h determined by s t e p (1).
(4) Compute t h e c o r e t h i c k n e s s , t C , using the f o r m u l a s
t +t
1 2
t = h -
C 2
tC = h -t (for equal f a c i D g s ) (9:7a)
The first approximation w a s based on a c o r e with a n infinite s h e a r mod-

ulus. Since actual c o r e s h e a r modulus v a l u e s a r e not v e r y l a r g e , a value
oft somewhat l a r g e r m u s t be used. S u c c e s s i v e approximations can b e
C
m a d e by e n t e r i n g f i g u r e s 9 - 1.to 9 - 8 with values of V o r W a s computed by
equations (9:2)and (9:3). F i g u r e s 9-1, 9-2, and 9-3 include c u r v e s for
sandwich with i s o t r o p i c and c e r t a i n orthotropic c o r e s . F i g u r e 9 - 4 applies
to s a n d w i c h w i t h i s o t r o p i c c o r e (R = i ) . F i g u r e 9 - 5 applies to sandwich
with orthotropic c o r e s f o r which the s h e a r modulus a s s o c i a t e d with the
panel width is O. 4 of the s h e a r modulus a s s o c i a t e d with the panel Length
(R 0.4). F i g u r e 9-6 applies t o sandwich with o r t h o t r o p i c c o r e s f o r which
the shear modulus a s s o c i a t e d with the panel width is 2 . 5 t i m e s the s h e a r
modulus associated with t h e panel length (R = 2, 5).
9-6

NOTE: F o r honeycomb c o r e s with c o r e ribbon p a r a l i e i
t o panel length a , G
C -- G T L and the s h e a r modulus
p a r a l l e l to panel width b is G F o r ho ne y C o m b c o r e s
TW'
with c o r e ribbons p a r a l l e l t o panel width b, G -
C - GTT.v
and the s h e a r modulus p a r a l l e l to panel length b i s
GTL'
F i g u r e 9-7 applies t o sandwich with c o r r u g a t e d c o r e having the c o r e

flutes p e r p e n d i c u l a r t o the panel edge of length a. F i g u r e 9 - 8 applies to
sandwich with c o r r u g a t e d c o r e having the c o r e flutes parallel t o the panei
edge of length a and r e q u i r e s v a l u e s of t h e p a r a m e t e r W given by equation
(9:3) o r (9:3a) instead of values of V.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Inusing f i g u r e s 9-1 to 9-8 f o r V o r W # O it i s n e c e s s a r y to i t e r a t e

because V o r W i s d i r e c t l y proportional to the c o r e thickness t As a n
C
.
aid to finaly d e t e r m i n i n g t
C
and G
C
, figure 9-9 p r e s e n t s a number of
l i n e s r e p r e s e n t i n g V o r W f o r v a r i o u s values of G with V o r W ranging
C
from O. O 1 to 2 and G ranging f r o m 1 , 0 0 0 t o 1 , 0 0 0 , 0 0 0 pounds p e r s q u a r e
C
inch. The following p r o c e d u r e i s suggested:
(a) D e t e r m i n e a c o r e t h i c k n e s s using a value of O. O 1 f o r V or W.
(b) Compute t h e constant r e l a t i n g V o r W to G or G -

C cb'
( c ) With t h i s constant, e n t e r f i g u r e 9 - 9 and d e t e r m i n e n e c e s s a r v

G or G
C cb'
(d) If the s h e a r modulus i s outside the r a n g e of values f o r m a t e r i a l s

available, s l i d e up the a p p r o p r i a t e line of f i g u r e 9 - 9 and pick a new value
of V or W, f o r r e a s o n a b l e value of c o r e s h e a r modulus.
( e ) R e e n t e r f i g u r e s 9-1 to 9-8 with the new v a l u e of V o r W and r e p a t

all previous ateps.
9-7

- __
MIL-JDBK-2 3A
9 March 1972 MIL-HDBK-23A C H G N O T I C E 3 W 9999970 0348059 921 m
9.3 DETERMINING CORE S E E A R STRESS
This saction gives the p r o c e d u r e f o r deterniininy, t h e i-riaxir:-,un c o r c

shear e t r s a e of a flat r e c t a n g u l a r sandwich panel uiiclcir i i n i f o r n i l y ciis-
trbuted normal load, The c o r e s h e a r s t r e s s i s maxiniiim a t the panel
edges, a t midlength of e a c h edge, T h e m a x i m u m s h e a r s t r e s s , F , is
cs
given by the f o r m u l a :
where K is a t h e o r e t i c a l coefficient dependent upon panel a s p e c t r a t i o

3
and the p a r a m e t e r V. i f the c o r e is i s o t r o p i c , values of V do not affect
the c o r e shear stress.
The c h a r t 8 of f i g u r e s 9-10, 9- 11 , and 9- 12 p r e s e n t a g r a p h i c a l s o l u -

tion of ( 9 : 8 ) . The c h a r t should be e n t e r e d with values of t h i c k n e s s e s and
o t h e r p a r a m e t e r s previously d e t e r m i n e d .
9.4 CHECKING PROCEDURES
T h e d e s i g n s h a l l be checked by using the g r a p h s of figUres 9 - 1 3

through 9-24 to d e t e r m i n e t h e o r e t i c a l coefficients K 2 , K i , K I , a n d K tc>
3
compute facing s t r e s s e s , deflection, and c o r e s h e a r s t r e s s e s . Ii t h e
g r a p h s do not apply to honeycomb c o r e because ratios of c o r e shear
moduli a r e far different f r o m those given on the g r a p h s , o r it i s d e s i r e d
to check by a m o r e a c c u r a t e a n a l y s i s , t h e f o r m u l a s given i n r e f e r e n c e ( 9 - 2 )
s h a l l be used. The g r a p h s f o r panels having c o r r u g a t e d c o r e apply t o
panels w h e r e t h e r a t i o of bending s t i f f n e s s e s , (Da/Db), is equal to 1.
If the c o r e c o r r u g a t i o n s contribute significantly to the panel bending stiff-
ness (D / D # 1 ) the g r a p h s given in r e f e r e n c e (9-3) should be used.
a b
9-8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

I
flIL-HDBK-23A CHG N O T I C E 3 7999970 0348060 6 4 3 -;=r,oi<-

9 Yirc?, 1Y;L
9.5 DETERMINING FACING THICKNESSy CGKE T E C K K Z S S ,

AND CORE SHEAR MODULUS FOR SIMPLY SGPPOAT'EZ
FLAT CIRCULAR P A N E L S
This section gives p r o c e d u r e s f o r d e t e r m i n i n g sandwich facing and ccrre

t h i c k n e s s e s and c o r e s h e a r modulus s o that chosen d e s i g n facing s t r e s s e s
and alIowable panel deflections w i l l not be exceeded ( r e f . 9-1). The facing
s t r e s s e s , produced by bending moment, a r e m a x i m u m at the c e n t e r of a
s i m p l y s u p p o r t e d c i r c u l a r panel under uniformly d i s t r i b u t e d n o r m a l load. If
r e s t r a i n t exists a t panel e d g e s , a r e d i s t r i b u t i o n of s t r e s s e s may c a u s e higher
stresses near panel edges. The p r o c e d u r e s given apply only to panels with
s i m p l y s u p p o r t e d e d g e s , i s o t r o p i c f a c i n g s , and i s o t r o p i c c o r e s . A solution
is p r e s e n t e d i n the f o r m of c h a r t s with which, by i t e r a t i v e p r o c e s s , the f a c -
ing and c o r e t h i c k n e s s e s and c o r e s h e a r modulus c a n be d e t e r m i n e d .
The a v e r a g e facing s t r e s s , F ( s t r e s s at facing c e n t r o i d ) , is given by the

theoretical formula:
2
F=--
3 + P P'
16 th (for equal facings) (5: 9.)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
w h e r e p is Poisson's r a t i o of facings ( i n f o r m u l a 9:9 it i s a s s u m e d that
p = p 1 pz); r is t h e r a d i u s of the c i r c u l a r panel; and other quantities a r e a s
previously defined ( s e e s e c t i o n 9.2).
Solving equations (9: 9) and (9:9a)f o r h gives -

r
h
I -
r
- I
( f o r equal facings) (9: Oa)
9-9

- _ ---
MIL-HBBK-23A CHG N O T I C E 3 9999970 O L 4 O b l 5 T
MIL-HDBK-23A
9 March 1972
A c h a r t for solving f o r m u l a s (9: 10) ana 9: 104) g r p h i c a l i y is give..-- i-; r:- . ..:: .
I . - 12
- 9 -
T h e formulas and c h a r t include i;he r a t i o t / h , Lchich is ~ s ~ i ,K\ ~ ; K ~ ~ L V ;.,-_

...
by i t e r a t i o n s a t i s f a c t o r y r a t i o s of t / h and h / r can L e Z o ~ i i a .
The-deflection, 6 , of the panel c e n t e r is given by the t n e r e t i c a l f c r m G i k :
6=K4 (+ 2tl, 2
E
-
h
2
E2, 1 2, 1 122
2
X F r
6 = 2K4 (for equal facings) ( 9 : 11aj
where K depends on the sandwich bending and s h e a r rigidities as incorporate.:

4
2
i n the p a r a m e t e r V =
T D which c a n be written as
( 2 r ) 2~
2
s r t E t E t
c 1 1 2 2
v. = i
4XrLG ( E l t i + E 2 t 2 )
C
2
IT t Et
C
V= (for equal facings) (5: 1 2 4
2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
. 8Xr G
c -
w h e r e r is panel .radius and all other t e r m s a r e a s previously de

Lined ic
s e c t i o n 9. 2.
Solving equations (9: 11) and (9: 1 la) f o r h gives
r
-
A c h a r t f o r solving f o r m u l a s (9: 13) and (9:13a) is given ir, f i g u r e -

of the equations and c h a r t s beyond 6 / h = O. 5 i s not recommended.
9 - 10

MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 8 0 6 2 4Lb
9 . 5. 1 U s e of Design Charts
.
The sandwich m u s t be designed by iterarivt? p r o c e u i x e b i ~ : . ~ ,.k: CL:;.^
enable r a p i d d e t e r m i n a t i o n of t h e v a r i o u s quantiries soug'rt. l i l e c k a r : ~ \\-ere
d e r i v e d for a P o i s s o n ' s r a t i o of the facings o i O . 3 and can be useG w i t h szzi1
e r r o r f o r facings having o t h e r values of P o i s s o n ' s r a t i o .
As a f i r s t approximation, i t w i l l be a s s u m e d that V = U. If tne design i s

controlled by facing s t r e s s c r i t e r i a , as m a y be d e t e r m i n e d , t h i s assumptiox
w i l l lead to an exact value of h. If the design is controiied "y deiec< d 'G r 1
r e q u i r e m e n t s , t h e a s s u m p t i o n that V = O w i l l produce a m i n i m u i n value oi R .
T h e value of h is m i n i m u m b e c a u s e V = O i f the c o r e s h e a r mrJOd.js is irGi:i:e.
F o r any actual c o r e , t h e shear modulus is not infinite; hence a tr,icker c 5 r e
m u s t be used.
(1) Enter f i g u r e 9 - 2 5 with t h e d e s i r e d value f o r the parameter -3

t
F
1,2
-
A s u m e a value for
- 2 .
122
h
-
and d e t e r m i n e h / r . Compute h a:d i
i , 2'
Mod: Y
.ratio -
h
2 i f n e c e s s a r y and d e t e r m i n e m o r e suitable values f o r n and t,
4
I, 2'
E t
L
(2) E n t e r figure 9-26 with d e s i r e d values of the p-a r a n e t e r s 7 and
h t
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
X F -L7 1 ;
- and a s s u m e V = O . A s s u m e a value f o r 6 / h and d e t e r m i n e k i r . C o z -
E2
pute h and 6 . Modify r a t i o 6 / h i f n e c e s s a r y and determir-e m c , ~ es u i t a s e
v a l u e s f o r h and .
( 3 ) Repeat s t e p s (1) and ( 2 ) , using lower chosel clesiK7, f a c : ? ~ s ; r v s i e ~ , ,

until h d e t e r m i n e d by s t e p (2) is equal t o , o r a bit i e s s t n a ~ ; T d e : e r : k ~ , e z
by s t e p ( 1 ) .
(4) Compute the c o r e thickness t , using tile f o r m u l a s

C
t i t
1 2
t = h -
C 2
t = h - t ( f o r equai f a c i n g s ; )
C
9-11

MIL-HDBK-23A CHG N O T I C E 3 7999970 OLYBOb3 352
MIL-HDBK-23A
9 March 1972
,. -
T h i s first approximation w a s b a s e d o n a CV:-L' w;: 1 : .-;i &:-.:LL: t s L ; ~ . . . ~
modulus. Since actual c o r e s h e a r m u d u l u s v-zlues r c l i i i j . . V~L-'; -ci: :i i.-. ; id. I <i
of t somewhat l a r g e r m u s t be usea. Successive apL3r<,:kA-rlL:ic,:.-,c,:.:~i>..:? :%--,-

C
by e n t e r i n g figure 9-26 with values of V as computed Gy eqtiafiorr3 (9: ;2; rid
(9: 12a).
In using f i g u r e 9-26 f o r V # O i t i s n e c e s s a r y t o iterate b e c a u s e iJ i-,

directly proportional to the c o r e thickness t C A s an aici t o f i n a l l y de:errrix-i- .
ing t
C
and G
C
, f i g u r e 9 - 9 c a n again be used. The constant re:ti-,g V t o C
C
may be computed f r o m t h e f o r m u l a
vc C =
r r2t E t E t
c 1 1 2 2
blr2(Eltl i E 2t 2
1 or (for equal i a c i n g s )
With this constant, f i g u r e 9-9 m a y be entered. Use of t h e f i g u r e is a s d e s -

c r i b e d i n section 9. 2, 1 .
9 . 6 DETERMINE CORE SHEAR STRESS
This s e c t i o n gives the p r o c e d u r e for determining t h e maxirniirri c o r e

s h e a r s t r e s s of a flat c i r c u l a r sandwich panel under uniformi>-d i s t r i s u t e d
n o r m a l load. The c o r e shear s t r e s s i s maxim-uni 21 the panei ei2ge. T h e
maximum s h e a r s t r e s s , F , is given by the formula:
cs
Pr ( 5 : 14)
= 2h
9.7 C H E C K I N G PROCEDURE
The design s h a l l be checked by c o m p u t i n g the f a c i n g s t r e s ~ e i;;.

. ~ cqi.i>.-
t i o n (9:?) and the deflection by equation (9: 11). The v a l u e of K L O be u s e d i:-i
-4
equation (9:1i) is given by
(9: i5;
W ich r e d u c e s t o K 5: O. 309 -t O. 491V when p = O. 3 . Talues of r mzy be c o m -

4
puted by equation (9: 12).
9 - 12
----
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
----____
-----
An a l t e r n a t e method f o r computing the del1ec;ion a: t3e p s n e i ce:.rcr -:
given by the formula:

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(9: 16a)
where
which r e d u c e s to K
5
= O. 629 +V when p = O. 3 .
The c o r e s e l e c t e d f o r the panel should be checked t o be s c r e that i t h a s

a c o r e s h e a r modulus value, G , at l e a s t as high as that a s s u m e d in comput-
C
If i t is d e s i r e d t o check by a m o r e a c c u r a t e a n a l y s i s , the f o r m u l a s given

i n r e f e r e n c e (9-1) s h a l l be used.
REFERENCED DOCUMEKTS
RAVILLE, MILTON E.
1968. G r a p h s f o r t h e Analysis of Simply Supported RectalEular

Sandwich.Plates Under Uniform T r a n s v e r s e P r e s s u r e .
Report C E / 2 1 / 6 8 . Dept. Civil Eng. , Southamptop Univ. ,
England.
9 - 13
---- - - --__
MIL-HDBK-23A C H G N O T I C E 3 9999970 0348065 3 2 5
-
MIL HDBK- 2 3A -
P
9 March I972
52
'I 2'1 99L'
Figure 9 - 1. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r flat r e c t z n g l a r
sandwich panel, with i s o t r o p i c f a c i n g s , tinder uniform;>- Ciscr.!;-:teL
normal load s o that facing s t r e s s w i l i 'be r".
9-i4
A t -
3.
--
~ _ - - - --`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 9-2. - - C h a r t f o r d e t e r m i n i n g h / h r a t i o f o r flat r e c t a c g u a r
sandwich panel, with i s o t r o p i c facings and a c o r r c p a t e d c o r e , c n d e r
uniformly d i s t r i b u t e d n o r m a l load C O that facing s t r e s s w:lj L e i--
9-15 ., 2

NIL-HDBK-23A CHG N O T I C E 3 E 9799970 O 3 4 8 0 6 7 T T 8 9
MIL-HDBK-23A
9 March 1972 P
6.2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 9-3. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r f l a t recta:igslar
sandwich panel, w i t h i s o t r o p i c facings and a corrGgateti c o r , ~ n d e r
uniformly d i s t r i b u t e d n o r m a l load s o that facing s t r e s s w i i : i ~ F- c -- -__
i , '
9- 16
------
II _-
. I
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 O348068 9 3 4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u. r e '9-4. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r flat r e c t a n g l a r
sa
d i s t r i bwith
ndwich panel,
uniformly u t e d inormal
s o t r o p i cload
facings and i s o
producing d terfol epci tci ocno rratio
e , under
6/h.

-- - ______
M I L - H D B K - 2 3 A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0148069 870 m
M IL-HDBK-23A
9 March 1972
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Y 132 99:
Figure 9-5. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r f l a t rectangillar

sandwich panel, with i s o t r o p i c f a c ingc a n d o r t h o t r o p i c ( s e e s k e t c h )
cere, u n d e r u n i f o r m l y d i s t r i b u t e d n o r m a l load producing deflection
ratio 6/h.
9-18

- _ _ ___ - ___ - __----
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
T
?I 132 Y93
F g u r e 9-6. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r ilat r e c t a i c - l a r
sandwich panel, with i s o t r o p i c a c i n g c and o r t h o t r o p i c ( s e e s k e t c . i ,
core, u n d e r u n i f o r m l y d i s t r i b u t e d n o r m a l load proc;itc 132 : L c-_ 2t e~i - : L ~ - > ; L
ratio /h.
9-1Y
______c ------------
_/

MIL-HBBK-23A CHG NOTICE 3 9999970 OI14807L 429 U
MIL- HDBK-2 3A
9 March 1972
O o.2 0.4 -b 0.6 O. 8

u
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
OJO O. 08 0.06 0.04 0.02

h
-
M 138 95: b
F i g u r e 9-7. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r f l a t recthngv:ar
sandwich panel, with i s o t r o p i c facings ana c o r r u g a t e d c o r e , ?u--- t3r
uniformly distributed n o r m a l load producing deilectior; r&t:z Z /?i.
9-20

- -~
- ~
~ _ _
flIL-HDBK-23A CHG N O T I C E 3 M 9999970 0148072 365
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
-. .
o./o- 0.08 0.06 0.04 o.02 o

-
h 131r 0% b
F i g u r e 9-8. - - C h a r t f o r d e t e r m i n i n g h / b r a t i o f o r flat rectarigu l a r

sandwich panel, with i s o t r o p i c facings and c o r r u g a t e d c o r e , under
uniformly d i s t r i b u t e d n o r m a l load producing deflection r a t i o 6 lh.
9-21

HIL-HDBK-23A CHG N O T I C E 3 9979970 0348073 2 T L
MIL-HDBK-23A
9 March 1972
. M d O A
9-22
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O148074 138 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
ATEDGE
C OF LEffGTH
I
-.... 1 ... I
I .....
I _. i I . 'I I I 1 I I
r
.L
sc
Figure 9-10. - - C h a r t f o r d e t e r m i n i n g c o r e s h e a r s t r e s s r a t i o - for
P
flat r e c t a n g u l a r eandwich panel, with i s o t r o p i c facings, u n d e r
uniformly d i s t r i b u t e d n o r m a l load,
9-23

- MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 1 4 8 0 7 5 074
MIL-KDBK-23A h
9 March 1972 5 Co
Q
Q o 3 6
M 138 969
. .. . . _
F
SC
Figure 9-1 1. - - C h a r t for d e t e r m i n i n g core s t r e s s r a t i o - f o r fiet
?
rectangular sandwich panel, with i s o t r o p i c facings and corr-:,u:cC.
core, under uniformly d i s t r i b u t e d load.
9-24
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ---_ __
NIL-HDBK-23A CHG N O T I C E 3 9999970 OL4807b T O O S
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
____A-
I - L
- h 138 958
F
SC
F i g u r e 9-12. - - C h a r t f o r d e t e r m i n i n g c o r e s h e a r s t r e s s r z t i o -
P ~C/T
_ -
flat r e c t a n g u l a r sandwich panel, with isotro?ic facings er.?:~ r : - i...I -
.
6
-
c o r e , under uniformly distribctfed normzi., LUZ?.

9-25

MIL-HDBK-23A
9 March 1972
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Figure 9-13.--K foi. determining facing s t r e s s , F , in b direction of flat

2
rectangular ganckich panels, with isotropic facings and isotropic or
orthotropic core (see sketch), under uniformly d i s tribute d normal load.
.. _. 9-26

MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 8 0 7 8 883 W
I I I I I I I I
3 O.4 0.6 O.8 /. O

-b
U
Figure 9-14. --K for d e t e r m i n i n g facing s t r e s s , F, in b d i r e c t i o n of

2
flat r e c t a n g u l a r sandwich panels, with i s o t r o p i c facings and c o r r u g a t e d
corFe(see s k e t c h ) , u n d e r uniformly d i s t r i b u t e d load.
9-27
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG NOTICE 3 m 9999970 0 1 4 8 0 7 9 71T m
MIL-HDBK-23A
9 Mar& 1972
0./41
o.I2
o. lo
0.08
L?
0.06
0.04
0.0;
Figure 9-15. --K f o r d e t e r m i n i n g facing s t r e s s , F, in the iJ directlo::

2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
of flat r e c t a n g u l a r sandwich panels, with i s o t r o p i c facings and corri:-

gated core ( s e e sketch), u n d e r uniformly distribi;ted load.
9-28
-- - - -.
-_
-- -
I
I l 1
I I
i j
I
1 Pb2 L
- 6,2=K2n7
18 2
- L / = - n2o
b2U j
I
i i
i
I
i ! i
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
i
1
l !
li j
f
0.08 l j f
Ii i
0.06,
I
I
!
i
I I
I
* !l 1
I
I l
O0
o.2 O. 4
-b O. 6 O. 8 1.o
A l ?IS 4 6 5 O
F i g u r e 9-16. --KI f o r d e t e r m i n i n g facing s t r e s s , F, in the a directLon

2
of flat r e c t a n g u l a r sandwich panels, with i s o t r o p i c facings and ortho
t r o p i c c o r e (see sketch) R = O. 4, under uniformly d i s t r i b u t e d load.
F o r R = 1 and R = 2.5 the m a x i m u m s t r e s s is given by K of Fig. 9 -
2
9-2 9

-_____.c__l______l___.____ .- - --- -- - -
MIL-HDBK-23A CHG NOTICE 3 m 9999770 0148081 378 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 9-17. --KI f o r d e t e r m i n i n g facing s t r e s s , F, in a d i r e c t i o n of

2
flat r e c t a n g u l a r sandwich p a n e l s , w i t h i s o t r o p i c a c l n g s and currligated
core (see s k e t c h ) , under uniformly d i s t r i b u t e d load.
9-30

flIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 1 4 8 0 8 2 204
!
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
i i
0.8 ' !
/. O
M 138 967 a
. Figure 9-18. --3$ for d e t e r m i n i n g facing s t r e s s , F, in a d i r e c t i o n of

flat rectangular sandwich panels, with i s o t r o p i c facings and c o r r c g a t e d
core (see sketch), under uniformly d i s t r i b u t e d load.
9-31

MIL-HDBK-23A CHG N O T I C E 3 M 9999970 014083 140 M
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

O. 014
o. 0/2
0.010
0.008
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
0.004
I I
- L/=- T 2 D
1 j I I, d
i
!
bU l !
I I I
L
I
O0 o. 2 0.4 O.6 O.8 /. O

-
X i I38 968 a
F i g u r e 9-20. - - K for. d e t e r m i n i n g m a x i m u m deflection, 6 , of flat

1
r e c t a n g u l a r sandwich panels, with i s o t r o p i c facings and c o r r u g a t e d
c o r e ( s e e sketch), u n d e r uniformly d i s t r i b u t e d load.
..
9-33

_____ ~ -
-
'
_ - - MIL-HDBK-23A CHG N O T I C E 3 70 0 3 4 8 0 8 5 T L 3
. ____
M i -HDBK-2 3A
9 March 1972
- -
?T'te D l I I
-W = I I
. -
bz h Z Geb !
; I i
I
-
5: 138 355 U
Figure 9-21. --K for d e t e r m i n i n g m a x i m u m deflection, 6 , of flat

1
r e c t a n g u l a r sandwich p a n e l s , w i t h i s o t r o p i c f a c i n g s and c o r r u g a t e d
c0r.e (see eketch), under uniformly d i s t r i b u t e d n o r m a l load.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
9-34
_ _ ~ - -

-_
I MIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 OL4808b 95T
___
0.5
0.4
G
0.3
0.2
O o.2 0.4 0.6 0.8
6
U
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 9-22.--K f o r d e t e r m i n i n g m a x i m u m c o r e s h e a r s t r e s s , F
3 sc
f o r f l a t r e c t a n g u l a r sandwich panels, with i s o t r o p i c facings and i s o -
t r o p i c o r orthotropic c o r e bsee sketch), u n d e r uniformly distributed
n o r m a l load.
9-35

MIL-HDBK-23A CHG NOTICE 3 = 9999970 0148087 896 W
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
._.
M I L - HDBK-23A
5 March 1972
F i g u r e 9-23. --K for d e t e r m i n i n g m a x i m u m c o r e shear s t r e s s , F

3 cs
f o r flat r e c t a n g u l a r sandwich panels, with isotropic facings and corru-
gated c o r e ( s e e s k e t c h ) , u n d e r uniformly d i s t r i b u t e d load.
5-36

MIL-HDBK-23A CHG N O T I C E 3 U 9 9 9 9 9 7 0 0 3 4 8 0 8 8 7 2 2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
./-
. .
- F9R SHEAR A
DGE OF L #Gil+ 0
I I I I
M I38 959
. .
Figure 9-24. --K f o r d e t e r m i n i n g m a x i m u m c o r e s h e a r s t r e s s , F ,

3 cs
for flat r e c t a n g u l a r sandwich panel, with i s o t r o p i c facings and c o r r u -
gated c o r e (see sketch), under uniformly d i s t r i b u t e d load.
9-37

MIL-HDBK-23A
9 March .1972
O 0.04 0.08 0./2 0.I6 0.20

-
h
r
H i32 997
Figure.9-25. - - C h a r t for d e t e r m i n i n g h / r r a t i o for flat c i r c u l a r sand-

wich panel, with i s o t r o p i c facings and c o r e , under uniformly d i s -
tributed n o r m a l Load so t h a t facing s t r e s s will be F , = O. 3 .
* u
1,2
9-38
-- ~
- _
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~
MIL-HDBK-23A C H G N O T I C E 3 E 9999970 O348090 380 =

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
o./2 0.08 004 O

-
h
f
H 132 998
. .
Figure 9-26. - - C h a r t f o r d e t e r m i n ng h / r r a t i o f o r flat c i r c u l a r sand-
wich, with i s o t r o p i c facings and c o r e , under uniformly d i s t r i b u t e d
normal load producing c e n t e r deflection r a t i o / h .
~-
. 9-39
-
\

M I L -H DB K - 2 3 A
30 Dec 1068
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
CHAPTER 10
DESIGN O F SANDWICH CYLINDERS CNDER
EXTERNAL RADIAL PRESSURE
Assuming t h a t a design begins with chosen design s t r e s s e s and a

given e x t e r n a l r a d i a l p r e s s u r e (110 a x i a l load), a c i r c u l a r cylinder lvith
w a l l s of sandwich c o n s t r u c t i o n s h a l l be designed to comply lvith the four
b a s i c d e s i g n p r i n c i p l e s s u m m a r i z e d in s e c t i o n 1 . 2 of the Introductior..
T h e s e four conditions m u s t be m e t .
O v e r a l l buckling of the sandwich w a l l s o r dimpling o r wrinkling of

the sandwich facings cannot o c c u r without possible c o l l a p s e of the c y l i n d e r .
Detailed p r o c e d u r e s , t h e o r e t i c a l f o r m u l a s , and g r a p h s f o r deterniining
dimensions of the facings and c o r e , as w e l l a s n e c e s s a r y c o r e p r o p e r t i e s .
a r e given in following p a r a g r a p h s , Double f o r m u l a s a r e gi\-en, one forixula
for sandwich with facings of different m a t e r i a l s and t h i c k n e s s e s and a n o t h e r
f o r sandwich with both facings of the s a m e m a t e r i a l and of e q u a l t h i c k n e s s .
Facing modulus of e l a s t i c i t y , E ' , and s t r e s s \,slues, F c , s h a l l be

c o m p r e s s i o n v a l u e s a t the conditions of u s e ; t h a t i s , i f application is a t
e l e v a t e d t e m p e r a t u r e , then facing p r o p e r t i e s at e l e v a t e d t e m p e r a t u r e s h a l l
be u s e d i n design. Tile facing modulus of e l a s t i c i t y is the effective value
of t h e facing s t r e s s . If the s t r e s s is beyond p r o p o r t i o n a l l i m i t v a l u e s , a n
a p p r o p r i a t e tangent, r e d u c e d , o r modified c o m p r e s s i o n modulus of
e l a s t i c i t y s h a l l be u s e d ( r e f , 1 0 - 3 ) .

NIL-HDBK-23A CHG N O T I C E 3 m 9 9 7 9 9 7 0 0248092 2 5 3 m
10.2 DETERMINING FACING THICKNESS, CORE THICKNESS,
AND CORE SHEAR MODULUS FOR SANDWICH
CYLINDERS UNDER EXTERNAL RADIAL PRESSURE
T h i s section p r e s e n t s f o r m u l a s , t h e o r e t i c a l equations, and a design

procedure to d e t e r m i n e the sandwich facing t h i c k n e s s , c o r e thickness , and
c o r e s h e a r modulus s u c h that o v e r a l l buckling of a sandwich cylinder will
not occur a t the chosen facing design s t r e s s e s . The equations and p r o c e d u r e
presented apply to sandwich c y l i n d e r s having facings of i s o t r o p i c m a t e r i a l s
and an i s o t r o p i c o r orthotropic c o r e . E n d s of the cylinder a r e a s s u m e d to
be simply supported on rigid plates that hold the ends c i r c u l a r . The facing
s t r e s s e s a r e r e l a t e d to the applied e x t e r n a l r a d i a l p r e s s u r e (no axial load)
by the equation:
tlFcl t t F (1O:l)
2 c2 = r p
t = -r-P (for equal facings) (1O:la)

2F
C
w h e r e t is facing t h i c k n e s s , F is chosen design hoop c o m p r e s s i v e facing

_._
.
stress, p is the design value 0% e x t e r n a l r a d i a l p r e s s u r e , r is the m e a n
radius of c y l i n d e r , and 1 , 2 a r e s u b s c r i p t s denoting facings 1 and 2.
In determining thickness of facings for sandwich with facings of dif-

f e r e n t m a t e r i a l s , equation 1O:l m u s t be s a t i s f i e d , but a l s o the s t r e s s e s
F and F m u s t be chosen s o that F c l / E s l = Fc2/Es2 ( w h e r e E is facing
cl c2 S
s e c a n t modulus of e l a s t i c i t y ) , thus avoiding o v e r s t r e s s i n g of e i t h e r facing.
F o r example, if facing 1 is a m a t e r i a l s u c h that the r a t i o F c l / E s l = 0 . 0 0 5
and facing 2 is a m a t e r i a l s u c h t h a t the r a t i o F = 0 . 0 0 2 , the design
c21Es2
m u s t b e b a s e d on a r a t i o of O. 0 0 2 ; o t h e r w i s e facing 2 will be o v e r s t r e s s e d .
In o r d e r to accomplish t h i s , the chosen design s t r e s s f o r facing 1 m u s t be
lowered. F o r many combinations of facing m a t e r i a l s , it w i l l be found
advantageous to choose t h i c k n e s s e s s u c h that E ' t = E ' t If the c o r e
1 1 2 2'
can support hoop c o m p r e s s i o n loads, r p should be r e p l a c e d by ( r p - F t ).
c c
10-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
y
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 1 4 8 0 9 3 09T
T h e load p e r inch of length due t o a n applied e x t e r n a l r a d i a l p r e s s u r e

at \vhich buckling of a sandwich c y l i n d e r o c c u r s i s given by the t h e o r e t i c a l
equation ( r e f . 10-1):
(10:2)
2E't
rp = -x ( f o r e q u a l facings) (10:Za)
whcarrl E ' i s effective c o m p r e s s i o n modulus of e l a s t i c i t y of the f a c i n g s ,

1 = 1 - p 2 , p is P o i s s o n ' s r a t i o of the f a c i n g s , and K is a t h e o r e t i c a l
cocsfficiclnt. Substitution of (10: 1) into (10:2) with t h e provision that s t r a i n
in facing 1 clquals s t r a i n in facing 2 r e s u l t s i n
( 10:3)
F X
- -C - K ( f o r raqua1 facings) (10:3a)
E'
Tlic. cocfficiviit K is dcipcndcnt upon c y l i n d e r dimensions and sandwich bend-

ing and s h e a r rigiditicls. Con\.cnic>ntnondimensional p a r a m e t c r s f o r d e t e r -
i D
mining K a r c h / r , L / r , E ' t / E f t 2 , and V = - \ v h t r e h i s dist;inccJ
1 1 2
r U
brt\vc.cn facing c c n t r o i d s , L i s c y l i n d e r length, D is sandlvich bending s t i f f -
n e s s , and U i s sandxs-ich s h e a r s t i f f n e s s . Substitution of e x p r e s s i o n s for D
and 1' into the p a r a m e t e r V r e s u l t s in
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
t E', t,E!,t,h
v =,
I l L L
1 1 (10:3)
[E'1t 1 t E f t 2 ] XrLGC
E ' th
V = ( f o r equal f a c i n g s ) (10:3a)
2
2Xr G
C
w h e r e G is the c o r e s h e a r modulus a s s o c i a t e d with s h e a r d i s t o r t i o n i n the

C
r a d i a l and c i r c u m f e r e n t i a l d i r e c t i o n s .

MIL-HDBK-23A CHG N O T I C E 3 9999970 OI148094 T 2 b =
1 0 . 2 . 1 Determination of Minimum Values of h
A m i n i m u m value of h r e q u i r e d w i l l be d e t e r m i n e d by a s s u m i n g
V = O f o r - a f i r s t approximation. The value of h is m i n i m u m b e c a u s e V = O
only i f the c o r e s h e a r modulus is infinite; f o r any actual c o r e the s h e a r
modulus is not infinite; hence a t h i c k e r c o r e m u s t be u s e d .
T h e c h a r t of figure 10-1 gives m i n i m u m values of h / r f o r sandwich

with i s o t r o p i c facings.
P a r a m e t e r s needed f o r u s e of the c h a r t a r e :
F x
c1,2 1 , 2
1. Facing p r o p e r t i e s ~,
2. Cylinder length-to-radius r a t i o L / r .
3. Ratio of -.
Eit2
F r o m the value of h the c o r e thickness i s computed by the f o r m u l a

tl f t
2
t = h - (10:4)
C 2
w
t = h - t (for equal facings) (10:4a)

C
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
10.3 FINAL DESIGN
The final sandwich design is a r r i v e d at by a s s u m i n g a slightly t h i c k e r

c o r e than d e t e r m i n e d in 10.2, 1 and using the checking c u r v e s of f i g u r e s
10-2 f o r Y = O , 10-3 f o r V = O. 05, and 10-4 f o r V = O. 10. The final design
s h a l l b e b a s e d on a buckling coefficient of O . 9 5 t i m e s the values given by
f i g u r e s 10-2 to 10-4 ( r e f . 10-2). S e v e r a l i t e r a t i o n s m a y b e n e c e s s a r y
b e c a u s e the p a r a m e t e r V is dependent upon sandwich thickness and c o r e
shear modulus a s given i n f o r m u l a (10:3). Interpolation f o r values of V
o t h e r than those given in the f i g u r e s can be done graphically.
10-4

__ -__
T h e f a m i l y of c u r v e s on f i g u r e 10-2 c a n be approximated v e r y closely

by a s i n g l e c u r v e f o r c y l i n d e r s of s h o r t and m o d e r a t e length. T h i s single
c u r v e shown i n f i g u r e 10-5 i s obtained by modifying the coordinate a x e s of
f i g u r e 10-2. F o r v e r y long c y l i n d e r s the single c u r v e b r a n c h e s into a
f a m i l y of l i n e s of s t e e p e r s l o p e , a s shown in t h e u p p e r right-hand portion of
f i g u r e 10-5. T h i s f a m i l y of l i n e s i s dependent upon the r a t i o r / h as well a s
t h e g r a p h a b s c i s s a . If t h e value of the a b s c i s s a i s s u c h t h a t the b r a n c h c d
l i n e s a r e shown, t h e value of the o r d i n a t e s h a l l be picked f r o m the branched
l i n e s r a t h e r than t h e bottom s t r a i g h t line. Thus f o r an a b s c i s s a of l o 5 and
( E ' t t Eitz)
1 1
r .fi-
a value of 100 f o r the p a r a m e t e r the p r o p e r value of
1 E;tlE>tZ h
the o r d i n a t e to produce the l e a s t buckling p r e s s u r e would be 3 . 0 5 x lo', not
1 . 6 4 x 10
2 .
If a m o r e a c c u r a t e d e t e r m i n a t i o n of K i s d e s i r e d , the a p p r o x i m a t e
f o r m u l a given i n r e f e r e n c e 10-1 can be solved. T h i s f o r m u l a i s
(10:5)
K =
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
2
where IC1
(10:6)
h2
42 =-
2
4r
Values of the n u m b e r of c i r c u m f e r e n t i a l b u c k l e s , n , a r e chosen to produce

m i n i m u m v a l u e s of K. T h i s a p p r o x i m a t e f o r m u l a does not contain t e r m s
with c o r e s h e a r moduli in the r a d i a l - a x i a l d i r e c t i o n s b e c a u s e t h e s e t e r m s
have little influence on c y l i n d e r s longer than about one d i a m e t e r . Thus the
c u r v e s given a p p r o x i m a t e the behavior of c y l i n d e r s with o r t h o t r o p i c a s w e l l
as i s o t r o p i c c o r e s .
10-5

MIL-HBEK-23A CHG N O T I C E 3 = 9999970 0348096 8 T 9
RE FE REN CE D DOCUMENTS
e
(10-1) KUENZI, E . W . , BOHANNAN, B . , a n d S T E V E N S , G . H .

1965. Buckling Coefficients f o r Sandwich Cylinders of F i n i t e Length
Under Uniform E x t e r n a l Lateral P r e s s u r e . U . S . F o r e s t
S e r v i c e R e s e a r c h Note F P L - 0 1 0 4 . F o r e s t P r o d . L a b . ,
Madison, W i s .
(10-2) NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

1965. Buckling of Thin-Walled C i r c u l a r C y l i n d e r s . NASA
SP-8007.

S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U . S . G o v .
P r i n t i n g Office, Washington,. D. C .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
10-6

RIb-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 0348097 735
'M 133 001

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 10-1. - - C h a r t f o r determining m i n i m u m h / r r a t i o ( V = O)
s u c h t h a t the walls of a sandwich cylinder with i s o t r o p i c facings
w i l l not buckle u n d e r e x t e r n a l r a d i a l p r e s s u r e (no axial load).

----
MIL-HBBK-23A CHG N O T I C E 3 m 9 9 9 7 9 7 0 OLL18098 671 m
c O.a
0.001
i
+
I
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I
/O I O
L
M/33'004
F i g u r e 1 0 - 2 . --Buckling coefficient K f o r sandwich cylinder u n d e r
e x t e r n a l r a d i a l p r e s s u r e . Isotropic facings; i s o t r o p i c o r ortho -
tropic core; V = O.
~~

IIL-HDBK-23A CHG N O T I C E 3 M 9 9 9 9 9 7 0 OL4BO99 50B M
i
I l
0-1 I
I
1 I j l
II
IO
-
L
r
, , ,
100
Ml33 003
-
F i g u r e 1 0 - 3 . --Buckling coefficient K f o r sandwich c y l i n d e r s u n d e r
e x t e r n a l r a d i a l p r e s s u r e . I s o t r o p i c facings; i s o t r o p i c o r o r t h o -
tropic core; V = 0 . 0 5 .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-- ~ _ _ _ _ _ __.- -___-___
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L 4 L O O 05T m
0.01
I I I I I I I I
o.m/
----+--
=E
t
I
O D
I /o
-
L
r
F i g u r e 10-4. --Buckling coefficient K f o r sandwich c y l i n d e r s u n d e r

external r a d i a l p r e s s u r e . I s o t r o p i c facings; i s o t r o p i c o r o r t h o -
t r o p i c c o r e ; V = O. 10.
-- - ____- - - ---
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

mIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L 4 L O L T 9 6 m
h
i ?
I I I _ . I . ?
I
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. .
.--
MIL-HDBK-23A CHG N O T I C E 3 9999970 0148102 922 W
MIL-HDBK-23A
3 0 Dec 1968
CHAPTER 11
DESIGN O F SANDWICH CYLINDERS
UNDE R TORSION

load to t r a n s m i t , a c y l i n d e r , with w a l l s of sandwich construction, under
t o r s i o n load s h a l l b e designed t o comply with the four b a s i c design p r i n c i -
ples s u m m a r i z e d i n 1.2 of the Introduction. In addition, i f the cylinder i s
e x t r e m e l y long, it s h a l l have sufficient bending stiffness s o that sideways
buckling will not o c c u r . T h e s e five conditions m u s t be m e t .
Buckling of the sandwich w a l l s , dimpling o r wrinkling of the facings, o r

sideways buckling of the cylinder cannot o c c u r without possible total collapse
of the cylinder. Detailed p r o c e d u r e s giving t h e o r e t i c a l f o r m u l a s and graphs
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f o r determining dimensions of the facings and c o r e , a s w e l l a s n e c e s s a r y

c o r e p r o p e r t i e s , a r e given in the following p a r a g r a p h s , Double f o r m u l a s
a r e given, one f o r m u l a f o r sandwich with facings of different m a t e r i a l s and
t h i c k n e s s e s and another f o r m u l a f o r sandwich with e a c h facing of the s a m e
m a t e r i a l and thickness. Facing modulus of c l a s t i c i t y , E ' ; s h e a r modulus,
G'; and s t r e s s v a l u e s , s h a l l be values a t the condition of u s e ; that i s ,
FS ,
i f application is at elevated t e m p e r a t u r e , then facing p r o p e r t i e s a t elevated
t e m p e r a t u r e s h a l l be u s e d i n design. The effective e l a s t i c modulus s h a l l be
the lower of e i t h e r the c o m p r e s s i v e o r t e n s i l e value of the facing m a t e r i a l
i n a direction at 45" to the cylinder axis. (The c o m p r e s s i o n and tension
s t r e s s e s , F and F a r e equal to the s h e a r s t r e s s , F f o r a tube in t o r s i o n . )
C t' S
If the s t r e s s is beyond the proportional limit value, a n a p p r o p r i a t e , tangent,

reduced, o r modified modulus of e l a s t i c i t y o r s h e a r modulus s h a l l be u s e d
( r e f . 11-5).
11-1

11.2 DETERMINING FACING THICKNESS
Facing s t r e s s e s a r e r e l a t e d to the applied t o r s i o n load by the equations:
t l F s l t t2Fs2 = N (for unequal facings) (1 1:l)
N
t=- (for equal facings) (i i:la)
2F
S
where t i facing thicknes , FS i s chosen design facing s h e a r s t r e s s , N is

design s h e a r load p e r unit length of cylinder c i r c u m f e r e n c e , and 1 , 2 a r e
s u b s c r i p t s denoting facings 1 and 2. N i s d e t e r m i n e d f r o m the design t o r q u e ,
T , by the f o r m u l a
T
N=- ( 1 1:2)
2
2rr
w h e r e r is m e a n r a d i u s of c u r v a t u r e of the sandwich cylinder walls.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
In determining thickness of facings f o r sandwich with facings of different
m a t e r i a l s , equation (1 1:l) m u s t be s a t i s f i e d , but a l s o the s t r e s s e s F and
sl
m u s t b e chosen s o t h a t F / G = Fs2/GsZ (where G i s facing s e c a n t
Fs2 sl sl
s h e a r modulus), thus avoiding o v e r s t r e s s i n g of e i t h e r facing. F o r e x a m p l e ,
i f facing 1 is a m a t e r i a l s u c h that F / G = 0 . 0 0 5 , the facing 2 i s a m a t e -
sl sl
rial such t h a t F = O. 002, the design m u s t be based on a r a t i o of
s2/Gs2
F s l / G s=l F s 2 / G s 2 = 0 . 0 0 2 ; o t h e r w i s e facing 2 will be o v e r s t r e s s e d . In
o r d e r t o accomplish t h i s , the chosen design s t r e s s f o r facing 1 m u s t be
l o w e r e d , F o r m a n y combinations of facing m a t e r i a l s i t will be found advan-
tageous t o choose t h i c k n e s s e s such that G t = G t o r E t = E 2 t 2 .
1 1 2 2 1 1
If the cylinder is long and s l e n d e r and the radius is l i m i t e d , the facing

t h i c k n e s s e s m a y have to be i n c r e a s e d i n o r d e r to prevent sideways buckling,
as c o v e r e d by section 11.4.
11-2
I

MIL-HDBK-23A CHG N O T I C E 3 9999970 O L Y B L O Y 7T5 =
11.3 DETERMINING CORE THICKNESS
T h i s s e c t i o n gives p r o c e d u r e s for determining c o r e thickness and c o r e

s h e a r modulus s o t h a t o v e r a l l buckling of the sandwich walls of the cylinder
w i l l not o c c u r (ref. 11-1, 11-2, 11-3). The facing s t r e s s at buckling i s
given by the f o r m u l a :
d
F
s1,2
= KE;,2 ; (11:3)
d
F S = KE' -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
r (for equal facings) (1 1 :3a)
w h e r e E ' is effective facing e l a s t i c modulus a t s t r e s s F ; d i s sandwich

S
t h i c k n e s s ; r i s m e a n r a d i u s of c u r v a t u r e ; and K is a t h e o r e t i c a l buckling
coefficient dependent on cylinder dimensions and sandwich bending and s h e a r
rigidities.
Values of the coefficient K a r e given by o r d i n a t e s of the c u r v e s i n the

upper portion of f i g u r e s 11-1 to 11-6 f o r sandwich with i s o t r o p i c facings
and i s o t r o p i c o r o r t h o t r o p i c c o r e s Determination of the coefficients w a s
b a s e d on the assumption that t h e P o i s s o n ' s r a t i o of the facings was O. 25.
F i g u r e s 11-1, 11-2, and 11 -3 a r e f o r sandwich with thin facings (t / d = 1)
C
and f i g u r e s 11-4, 11-5, and 11-6 f o r sandwich with m o d e r a t e l y thick facings
(t / d = 0.7). The c u r v e s give approximate values f o r cylinders of sandwich
C
with c o r r u g a t e d c o r e s . M o r e a c c u r a t e data f o r s u c h sandwich cylinders a r e
given i n r e f e r e n c e s (11-1) and (11-2). F i n a l design values of K s h a l l be 0.75
t i m e s the values given by f i g u r e s 11-1 to 11-6 ( r e f . 11-4).
Solving equations (11:3) and ( l l : 3 a ) f o r d / r gives:
F
d s1.2 : i i (11:4)
-
d -
- 1 S
(for equal facings) (11:4a)
r E'
11-3

MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 7 9 7 0 O l l t 1 0 5 631 =
\
e Therefore,if K is known, equation (1 1 :4) o r (1 1 :4a) can be solved d i r e c t l y
to eventually obtain d b e c a u s e a l l other quantities a r e known. After d is
obtained, the c o r e t h i c k n e s s , t , is computed f r o m the f o r m u l a s
C
t
C
= d - (ti t t2) (1 1:5)
t
C
= d - 2t (for equal facings) ( i 1 :5a)
Values of K depend upon the bending s t i f f n e s s , D, and s h e a r s t i f f n e s s ,

U , of the sandwich a s i n c o r p o r a t e d i n the p a r a m e t e r
v = - D2
r U
which c a n be w r i t t e n a s :
E;tlESt2h
V = - (1 1:6)
( E ; t l t E ' t I XrLGC
2 2
E ' th
V = 2 (for equal facings) (1 1 :6a)
2Xr G
C
2
w h e r e h i s distance between facing c e n t r o i d s , X = 1 p , p i s P o i s s o n ! s -
r a t i o of facings, and G i s c o r e s h e a r modulus a s s o c i a t e d with s h e a r d i s -
C
t o r t i o n in the r a d i a l and axial d i r e c t i o n s . Values of K a r e a l s o dependent
upon the cylinder g e o m e t r y a s r e p r e s e n t e d conveniently by dimensionless
p a r a m e t e r s L / r , d / r , and J = L 2 / d r .
11.3.1 Determination of Minimum Values of d
A m i n i m u m value of d r e q u i r e d will be d e t e r m i n e d by a s s u m i n g V = O
f o r a first approximation. The value of d i s m i n i m u m because V = O only i f
the c o r e s h e a r modulus is infinite; f o r any actual c o r e the s h e a r modulus is
not infinite; hence, a t h i c k e r c o r e m u s t be used.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
11-4
--_---------.-~
Provided by IHS
.
-
______-
NIL-HDBK-23A CHG N O T I C E 3 m 9 9 7 9 9 7 0 O L 4 L O b 578 m
The c h a r t s of f i g u r e s 11-1 to 11-3 give values f o r d / r f o r s a n d w i c h w i t h

thin, equal, i s o t r o p i c facings o r f o r sandwich with thin i s o t r o p i c facings
such that E ' t = E ' t The c h a r t s of f i g u r e s 11-4 to 11-6 apply to s i m i l a r
1 1 2 2'
sandwich with m o d e r a t e l y thick facings, Minimum values of d / r a r e obtained
f r o m t h e c u r v e s f o r V = O. The u p p e r portion of the c h a r t s i s e n t e r e d with
the a p p r o p r i a t e s t r a i g h t line r e p r e s e n t e d b y the known value of a p a r a m e t e r
(11:7)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
The i n t e r s e c t i o n of this a p p r o p r i a t e line with the c u r v e f o r V = O in the

u p p e r g r a p h o c c u r s at an a b s c i s s a value of J which is solved graphically f o r
any p a r t i c u l a r L / r r a t i o to give the m i n i m u m d / r r a t i o in the lower g r a p h
of the figure s.
11.3.2 Determination of Actual Values of d
Since a c t u a l c o r e s h e a r modulus values a r e not v e r y l a r g e , a value of d

somewhat g r e a t e r than given i n 11.3.1 m u s t be used. The f i g u r e s 11-1 to
11-6 a r e e n t e r e d at c u r v e s with values of V as computed by equation (1 1 :6)
o r (11:6a). F i g u r e s 11-1 and 11-4 apply t o sandwich with i s o t r o p i c c o r e s
f o r which the c i r c u m f e r e n t i a l s h e a r modulus i s equal to the axial s h e a r
modulus. F i g u r e s (11-2, 11-5) and (11-3, 11-6) apply t o sandwich with
o r t h o t r o p i c c o r e s for which the c i r c u m f e r e n t i a l s h e a r modulus is equal to
O. 40 and 2.50 t i m e s , r e s p e c t i v e l y , the axial s h e a r modulus.
NOTE: F o r honeycomb c o r e s with c o r e ribbons p a r a l l e l to the cylinder

axis, G and the c i r c u m f e r e n t i a l s h e a r modulus is G F o r honey-
C = G~~ TWO
c o m b c o r e s with c o r e ribbons c i r c u m f e r e n t i a l , G = G T W and the c i r c u m -
C
f e r e n t i a l s h e a r modulus is G
TL'
I n using f i g u r e s 11-1 to 11-6 it i s n e c e s s a r y to i t e r a t e b e c a u s e V is

d i r e c t l y proportional t o the c o r e t h i c k n e s s , t .
A s a n aid t o finally d e t e r -
C
mining t and G , f i g u r e 11-7 p r e s e n t s a n u m b e r of l i n e s representing V
C C
f o r v a r i o u s values of G with V ranging f r o m 0.01 to 2 and G ranging f r o m
C C
1 , 0 0 0 to 1 , 0 0 0 , 0 0 0 pounds p e r s q u a r e inch. T h e following p r e c e d u r e is
suggested:
11-5
- ------ --- --

MIL-HBBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 O L L i B L O 7 Li04 =
1. D e t e r m i n e a thickness d f r o m figures 11-1 to 11-6 using a value of
0.01 f o r V.
2. Compute t h e constant r e l a t i n g V to G
C
.
r 1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
3. With this constant e n t e r f i g u r e s 11-7 and d e t e r m i n e n e c e s s a r y G I

C
4. If t h e s h e a r modulus i s outside the range of values f o r the m a t e r i a l s

available, s l i d e u p the a p p r o p r i a t e line of figure 11 -7 and pick u p a new
value of V , f o r a r e a s o n a b l e value of c o r e s h e a r modulus.
5. Reenter f i g u r e s 11-1 t o 11-6 with t h e new value of V and r e p e a t

previous s t e p s 1 , 2 , and 3.
11.3.3 Checking P r o c e d u r e f o r Determining Buckling S t r e s s , F

scr
-
The design s h a l l be checked by using t h e g r a p h s of figures 11-1 to 11-6
t o d e t e r m i n e values of K to substitute into f o r m u l a (11:3) o r (1 1:3a) to c o m -
pute a c t u a l buckling s t r e s s , F
scr
.
11.4 CHECK TO DETERMINE WHETHER
SIDEWAYS BUCKLING WILL OCCUR
If the sandwich cylinder is f a i r l y long it may buckle sideways s i m i l a r to

the way a column buckles u n d e r end c o m p r e s s i o n . The load p e r unit length
of circumfer'ence at which sideways buckling will o c c u r i s given approximately
by the f o r m u l a :
TT (Eltl t E>t2)r
N = (1 1:8)
cr 2L
TE' tr
N =- (for equal facings) (ll:8a)
cr L
11-6

~-
MIL-HBBK-23A CHG N O T I C E 3 W 9997970 O L 4 L O 8 3 4 0 W

b
e
If the value of N as computed by f o r m u l a (11:8) is l e s s than the design
cr
load, the cylinder w i l l have to be redesigned by using a l a r g e r r a d i u s ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
s h o r t e r length, o r s t i f f e r facings. F o r m u l a (11:8) w a s d e r i v e d f o r thin-

walled cylinders and is about 3 p e r c e n t in e r r o r f o r h / r = 0.2. For
h / r ~ 0 . 2 , the e r r o r is l e s s than 3 percent.
1-1) BAKER, E.
1964. Stability of C i r c u m f e r e n t i a l l y C o r r u g a t e d Sandwich Cylinders
Subjected to Combined Loads. AIAA J o u r n a l , Vol. 2 , No. 12.
(11-2) HARRIS, L . , and BAKER, E.

1962. E l a s t i c Stability of Simply Supported C o r r u g a t e d C o r e Sand-
wich Cylinders. NASA Tech. Not D-1510.
(11-3) MARCH, H. W., and KUENZI, EDWARD W.

1958. Buckling of Sandwich Cylinders in Torsion. U.S. F o r e s t Prod.
Lab. Rep. No. 1840.
(11-4) NATIONAL AERONAUTICS AND SPACE ADMINISTRATION.

1965. Buckling of Thin-Walled C i r c u l a r Cylinders. NASA SP-8007.
(11-5) U.S. DEPARTMENT O F DEFENSE.

C u r r e n t Metallic M a t e r i a l s and E l e m e n t s f o r A e r o s p a c e Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U . S . Gov.
P r i n t i n g Office, Washington, D. C.
11-7
- - ----- .L
--,
i

MIL-MDBK-23A CHG NOTICE 3 9999970 01148309 2 8 7 =
3.o
2.o
/.O
O.8
0.6
t
O.4
o.2
o.f
/o /o' I
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o.I
O.08
O.06
o.o4
o.o2
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o.Of
0.008
O.006
0.004 -
J ='-L
rd -
0.002
o.OOf
,
134 9 1 2 :
-
F i g u r e 1 1 1. - - C h a r t for d e t e r m i n i n g a - d r a t i o s u c h that a sandwich
r
c y l i n d e r with i s o t r o p i c c o r e w i l l not buckle; - tC = 1.
d
/--'

-~ ~ __ -~
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L 4 L L O T T 9 m
1
o.I
O.08
0.06
0.04
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
o.o2
o.o1
0.008
0.006
0.004
0.002
I \ I \ \
o.O01
34 134 915
d
Figure 11-2. --Chart for determining a -
r
ratio such that a sandwich
tC
cylinder with orthotropic core w i l l not buckle; -
d
= 1.
------------- -
~~
Y

- --_
NIL-HDBK-23A CHG N O T I C E 3 H 9 9 9 9 9 7 0 O L 4 L L L 935 H
/O I J
IO 3 IO
O./
1
0.08
O.06
O.04
o.02
o.o/
0.008
O. 006
.
0.004
0.002 -- --- - . -
o.001 I
d
,
N 1 3 4 917
F i g u r e 11-3. - - C h a r t f o r d e t e r m i n i n g a -
d r a t i o s u c h t h a t a sandwich f
r
cylinder with o r t h o t r o p i c c o r e will not buckle; - tc
d
= 1. .
.%
------- ______
I
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- -
3.O
2.o
1.O
O.8
0.6
0.4
o.2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O./
J
I
O./
0.08
0.06
0.04
o.o2
o.o/
O.008
0.006
0.004
o.O02
o.oo/
M I
d
F i g u r e 11-4. - - C h a r t f o r determining a - r r a t i o s u c h that a sandwich
tc
cylinder with i s o t r o p i c c o r e will not buckle; - d = 0.7.

NIL-HDBK-23A CHG N O T I C E 3 9999970 CIL48113 708
3.O
00
2.o
00
/.0
O.8
t O.6
O.4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O.2
o.
- ..I
IO IO * 1
o.I
"I
O. 08
0.06
O.O4
o.oz
'blC o.o/
O.008
0.006
0.004
0.002
o. O01
M 134 913
-
F i g u r e 11-5. - - C h a r t for d e t e r m i n i n g a d r a t i o s u c h that a sandwich - --
r
cylinder with orthotropic c o r e w i l l not buckle; t C = 0.7. -
d

-
HIL-HDBK-23A CHG N O T I C E 3 7999770 O L 4 L L 4 6 4 4
3.O
2.o
I.o
O.8
L O.6
0.4
o.2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
'0
H 134 916
F i g u r e 11-6. - - C h a r t f o r d e t e r m i n i n g a -dr r a t i o s u c h t h a t a sandwich -

tC
cylinder w i t h o r t h o t r o p i c c o r e w i l l .not buckle; - = 0.7.
--_ d
----------'-
i '
.
I Provided by IHS
MIL-HDBK-23A CHG NOTICE 3 9999970 OL48LL5 5 8 0
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK -23 A
30 Dec 1968
CHAPTER 12
DESIGN O F SANDWICH CYLINDERS UNDER AXIAL
COMPRESSION OR BENDING
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

load to t r a n s m i t , a cylinder with walls of sandwich construction under axial
c o m p r e s s i o n o r bending load s h a l l be designed t o comply with the four basic
design principles s u m m a r i z e d in 1. 2 of the Introduction. In addition, if the
cylinder i s c o m p r e s s e d axially, the e n t i r e cylinder s h a l l have sufficient
bending stiffness s o that buckling a s a long column will not o c c u r .
O v e r a l l buckling of the cylinder o r the sandwich walls o r dimpling o r

wrinkling of the facings cannot o c c u r without possible total collapse of the
cylinder. Detailed p r o c e d u r e s giving t h e o r e t i c a l f o r m u l a s and graphs f o r
determining dimensions of the facings and c o r e , as well as n e c e s s a r y c o r e
p r o p e r t i e s , a r e given in following p a r a g r a p h s , Double f o r m u l a s a r e given,
one f o r m u l a f o r sandwich with facings of different m a t e r i a l s and thicknesses
and another f o r m u l a f o r sandwich with each facing of the s a m e m a t e r i a l and
thickness. Facing modulus of e l a s t i c i t y , E ' , and s t r e s s v a l u e s , F , s h a l l
C
b e c o m p r e s s i o n values at t h e condition of u s e ; that i s , i f application i s a t
elevated t e m p e r a t u r e , then facing p r o p e r t i e s a t elevated t e m p e r a t u r e shall
be u s e d in design. T h e facing modulus of e l a s t i c i t y i s the effective value a t
the facing s t r e s s . If this s t r e s s is beyond the proportional l i m i t value, an
a p p r o p r i a t e tangent, reduced, o r modified c o m p r e s s i o n modulus of elasticity
s h a l l b e u s e d ( r e f . 12-8).
12.2 DETERMINING FACING THICKNESSES
Facing s t r e s s e s a r e r e l a t e d to the axial load by the equations:
12-1

MIL-HDBK-23A CHG N O T I C E 3 = qqqqq70 O L 4 B 1 1 7 353
= N ( f o r unequal f a c i n g s ) (12:l)
tlFcl + t2Fc2
N
t=- (for equal f a c i n g s ) (12 :1a)
2F
C
w h e r c t i s facing t h i c k n e s s , F is chosen design facing c o m p r e s s i v e s t r e s s ,

C
N is design c o m p r e s s i o n load p e r unit length of cylinder c i r c u m f e r e n c e , and
1 . 2 arc' s u b s c r i p t s denoting facings 1 and 2 . If the load i s produced by bend-
ing m o m e n t the relationship between m a x i m u m N and bending m o m e n t , M ,
2
f o r a cylinder of m e a n r a d i u s , r , is given by N = M / r r .
In determining thicknesses of facings of d i f f e r e n t m a t e r i a l s , equation

( 1 2 : l ) ' m u s t be s a t i s f i e d , but a l s o the s t r e s s e s F and Fc2 m u s t be chosen
cl
so that F / E - (Lvhere E is facing s e c a n t modulus of e l a s t i c i t y ) ,
c l . 5 1 - Fc2/Es2 S
thus avoiding o v c r s t r c s s i n g of e i t h e r facing. F o r e x a m p l e , i f facing 1 is

a m a t e r i a l s u c h that the r a t i o F / E = O. 0 0 5 and facing 2 i s a m a t e r i a l
cl sl
such t h a t the r a t i o F = 0 . 0 0 2 , the design m u s t be b a s e d on a r a t i o
c 2 5 2
of 0 . 0 0 2 : o t h e r u i s c facing 2 will be o v e r s t r e s s e d . In o r d e r to accomplish
t h i s , t h c chosen design s t r c s s f o r facing 1 m u s t be lowered. F o r many --
combinations of facing m a t e r i a l s , it will be found advantageous to choose
thicknc,sscs s u c h t h a t E t = E t If the c o r e can s u p p o r t edge load, N
1 1 2 2'
should be r e p l a c e d by t h e quantity (N - F t ) .
c c
If an axially c o m p r r s s t l d cylinder is long and s l e n d e r and t h e r a d i u s is

l i m i t e d , the facing thicknesses m a y have to be i n c r e a s e d in o r d e r t o prevent
column buckling, a s c o v e r e d by section 12. 5 .
-12.3 DETERMINING CORE THICKNESS

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
This section gives p r o c e d u r e s f o r d e t e r m i n i n g c o r e thickness and c o r e

s h e a r modulus s o that o v e r a l l buckling of the sandwich w a l l s of the cylinder
will not o c c u r (refs. 12-1, 1 2 - 2 , 1 2 - 3 , 1 2 - 4 , 12-7, and 12-10).
12-2

-
MIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 7 7 0 O L 4 L L 2 7 T W
b
e T h e o r e t i c a l f o r m u l a s a r e b a s e d on buckling load f o r c l a s s i c a l sine-wave
buckling. The theory defines the p a r a m e t e r s involved r a t h e r than d e t e r m i n e s
e x a c t coefficients f o r computing buckling loads, L a r g e d i s c r e p a n c i e s e x i s t
between t h e o r y and t e s t s and unfortunately the t e s t values f o r buckling of thin-
walled cylinders i n a x i a l c o m p r e s s i o n o r bending a r e m u c h lower than
expected by theory (refs. 12-5, 12-6). P r e v i o u s design information ( r e f . 12-91
b a s e d on a large-deflection theory and diamond-shaped buckles gave r e s u l t s
less than one-half the buckling loads given by c l a s s i c a l theory. Continued
efforts in s h e l l analysis have shown that the post-buckling behavior tends to
approach m u c h lower l i m i t s .
Until sufficient t e s t data a r e available, reduction f a c t o r s m u s t be applied

t o t h e o r e t i c a l buckling coefficients. T h e s e reduction f a c t o r s attempt to
account f o r effects of initial s h e l l i r r e g u l a r i t i e s , and thicker s h e l l s have
l e s s reduction f r o m c l a s s i c a l theory than thinner s h e l l s ( r e f s . 1 2 - 4 and 12-5).
Reduction f a c t o r s , k , which a r e 95% of f a c t o r s given in r e f . 12-4, a r e p r e -
sented in figure 12-1 a s a function of the r a t i o of m e a n cylinder r a d i u s , r ,
to the cylinder wall r a d i u s of gyration, p .
The following p r o c e d u r e s a r e applicable to cylinders longer than the

length of one ideal buckle, s u c h a s would f o r m i n the wall of a long cylinder.
G e n e r a l l y , the i d e a l buckle length i s about equal to the radius of the cylinder
i f the c o r e s h e a r modulus i s high. It b e c o m e s s h o r t e r than the radius a s the
c o r e s h e a r modulus d e c r e a s e s .
The load p e r unit cylinder c i r c u m f e r e n c e at which buckling of the s a n d -

wich w a l l w i l l o c c u r is given by the f o r m u l a :
v p ; t l + E f t 'i D
N = 2kK 2 21 (12:2)
cr r
w h e r e k is a reduction f a c t o r given in f i g u r e 12-1, D i s the sandwich bending

s t i f f n e s s , r is m e a n radius of c u r v a t u r e , and K i s a t h e o r e t i c a l buckling
coefficient dependent on sandwich bending and s h e a r r i g i d i t i e s . T h i s f o r m -
u l a solved f o r the facing s t r e s s b e c o m e s :
kKE
-- 182
(12:3)
Fc1,2
-6- E't +Eft
1 1 2 2
F = -kKE'
-- h
(for equal facings) ( 12 :3 a)
= V
-.
12 -3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__ -
MIL-HDBK-23A CHG N O T I C E 3 W 9 9 7 9 9 7 0 OL4B119 126
i
L
w h e r e E is effective c o m p r e s s i v e modulus of e l a s t i c i t y a t s t r e s s F ;
C
2
A = 1 -
p ; p is P o i s s o n s r a t i o of facings (in f o r m u l a s given h e r e it i s
a s s u m e d p = p l = p 2 ) ; and h is distance between facing c e n t r o i d s .
Values of the c o e f f i c i e n t K a r e given by the following approximate

formulas:
F o r sandwich with i s o t r o p i c o r honeycomb c o r e o r c o r r u g a t e d c o r e

with flutes c i r cumf e r entia1- -
= - FJ v ( f o r equal facings)
(12:5) 7
1
K = ( f o r equal facings)
F o r sandwich with c o r r u g a t e d c o r e having flutes a x i a l - -

I
(12:6)
(for equal facings) ( 12 : 6a)
Et
2 2
where R = -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
E:t,E:t? h
I l L L
V = I ( I 2:7)
E th
V = (for equal f a c i n g s ) ( 1 2 :7 a)
2
2Xr G
C
12 -4
__---I_-
------

b
t
E ;tlEit2 h
W = (12:8)
X r 2 (.it, t E;t2j GI
C
E I th
W = (for equal facings) (12:8a)
2
2Xr GI
C is the c o r e s h e a r modulus a s s o c i a t e d with the directions axial to the

C
cylinder and perpendicular to the wall of the cylinder and G ' is the c o r e
C
s h e a r modulus a s s o c i a t e d with the d i r e c t i o n s c i r c u m f e r e n t i a l to the cylinder
and perpendicular to the wall of the cylinder. A s values of c o r e s h e a r m o d -
ulus d e c r e a s e , values of V o r W i n c r e a s e and values of K gradually d e c r e a s e .
Solution of f o r m u l a (12:3) f o r h / r a f t e r substitution of e x p r e s s i o n s f o r K

f r o m f o r m u l a s (12:4) and (12:6) r e s u l t in
I .' ru x
c1,2 1 , 2
(12:9)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F
_h -- -CA
t v (for equal facings) ( 12 :9 a )
r kE'
or
(12: 1o)
h L ~ X W
-r ---E ' 4
+- ( f o r equal facings) ( 12 : 1O a )
To d e t e r m i n e values of h it is n e c e s s a r y to i t e r a t e because k and V o r W

a r e dependent upon h. A first i t e r a t i o n to d e t e r m i n e a m i n i m u m value of h
can b e m a d e f r o m f o r m u l a (12:9) o r (12:lO) and the g r a p h of figure 12-1 by
a s s u m i n g V = O o r W = O. This v a l u e of h is a m i n i m u m b e c a u s e V = O o r
W = O only i f the c o r e s h e a r modulus is infinite; f o r any actual c o r e the
s h e a r modulus is not infinite, hence a t h i c k e r c o r e m u s t be u s e d . Values
of V o r W a r e a l s o dependent upon c o r e s h e a r modulus, G (see f o r m u l a s
C
L2:7 and 12:8). A s a n aid to finally determining h and G , figure 12-2 p r e -
C
s e n t s lines r e p r e s e n t i n g V or W for v a r i o u s values of G
C
.
-
12-5
I
t
MIL-HDBK-23A
P
CHG NOTICE 3 = 9999970 0148121 8 8 4 =
1. A s s u m e V o r W e q u a l t o z e r o , k e q u a l to O. 6 , and compute a value of

h f r o m f o r m u l a (12:9) o r (12:lO).
2. E n t e r f i g u r e 1 2 - 1 with a value of r / p b a s e d on the computed value of

h and d e t e r m i n e a new value of k. (p i s defined i n f i g u r e 1 2 - 1 . )
3. Recompute a value of h f r o m f o r m u l a s (12:9) o r (12:lO) using the

value of k d e t e r m i n e d i n S t e p 2.
4. R e p e a t S t e p s 2 and 3 until t h e value of h computed in S t e p 3 a g r e e s

with t h a t u s e d in S t e p 2.
5. A s s u m e a s m a l l value of V o r W and r e p e a t previous s t e p s to d e t e r -

m i n e a somc\vhat l a r g e r value of h.
6. Compute t h e c o n s t a n t r e l a t i n g V o r W to G :
C
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
E't E't h
1 1 2 2
= VG o r WG
C C
i h r 2 k i t l f E 2' t2
i;;;;-]
E'th = VG o r WG
C
(for equal facings)
7. With t h i s c o n s t a n t , e n t e r f i g u r e 12-2 and d e t e r m i n e n e c e s s a r y G

C
.
8. If the s h e a r modulus is outside the range of v a l u e s f o r m a t e r i a l s
a v a i l a b l e , s l i d e u p the a p p r o p r i a t e line of f i g u r e 1 2 - 2 and pick a new
value of V o r W f o r a r e a s o n a b l e value of c o r e s h e a r modulus.
9. Recompute h with a new v a l u e of V o r W and r e p e a t p r e v i o u s s t e p s

until the value of h is obtained.
10. Calculate c o r e t h i c k n e s s t f r o m t h e equations

C
tl f t
2
t = h - (12:ll)
C 2
t
C
= h - t (for equal f a c i n g s ) ( 12:1 1a)
12-6

MIL-HDBK-23A CHG N O T I C E 3 = 9999970 OL4L22 710 =
12.4 CHECKING PROCEDURE FOR DETERMINING
CYLINDER WALL BUCKLING STRESS, F

cr
' T h e design s h a l l be checked by using the g r a p h of figure 12- 1 to obtain k

values and f o r m u l a s (12:4), (12:5), o r (12:6) to obtain K to substitute into
f o r m u l a (12:3) o r (12:2) to compute the buckling s t r e s s F
cr
o r end load N
cr
.
T h e f o r m u l a s apply to sandwich cylinders having i s o t r o p i c facings and i s o -
t r o p i c honeycomb, o r c o r r u g a t e d c o r e s a s noted. It should be understood
t h a t i f the d e s i r e d F i s above proportional l i m i t v a l u e s , the value of E '
cr
s h a l l be an effective value u s e d i n computing V and in computing F .
cr
12.5 CHECK TO DETERMINE WHETHER

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
COLUMN BUCKLING WILL OCCUR
If a n axially c o m p r e s s e d sandwich cylinder i s f a i r l y long, i t m a y buckle

as a column. The facing s t r e s s a t which E u l e r column buckling w i l l o c c u r ,
i f the ends of the cylinder a r e hinged, is given by the f o r m u l a :
2 2
TI r E'
F -- 15.2
(12:12)
el, 2
2 L2
w h e r e L is the unsupported column length and e denotes E u l e r . The load

p e r unit length of c i r c u m f e r e n c e of the cylinder i s given by:
(12:13)
2 2
TT r E't
Ne = (for equal facings) ( 1 2 :13a)
L2
If the value of N a s computed by f o r m u l a (12: 13) is l e s s than the design

e
load, the cylinder will have to be redesigned by using a longer r a d i u s ,
s h o r t e r length, o r s t i f f e r facings. The f o r m u l a s (12:12) and (12:13) w e r e
d e r i v e d f o r thin-walled cylinders and a r e about 3 p e r c e n t in e r r o r f o r
_h -- O . 2. F o r -< h
0 . 2 , the e r r o r i s l e s s than 3 p e r c e n t .
r r
12-7

__--
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L q B l 1 2 3 657 m
(12-1) BAKER, EDWARD H.

1964. Stability of C i r c u m f e r e n t i a l l y C o r r u g a t e d Sandwich Cylinders
Under Combined Loads. AIAA J o u r n a l Vol. 2 , NO. 12.
(12 -2) FULTON, ROBERT E .

1965. Effect of F a c e - S h e e t Stiffness on Buckling of Curved P l a t t s
and Cvlindrical S h e l l s of Sandwich Construction in Axial
C o m p r e s s i o n . NASA T e c h . Note D-2783.
(12 - 3 ) HARRIS, LEONARD A . , and BAKER, EDWARD H.

1962. E l a s t i c Stability of Simply Supported Corrugated C o r e
, Sandwich Cylinders. In Collected P a p e r s on Instability of
Shell S t r u c t u r e s , NASA Tech. Note D-1510.
(12-4) NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

1965. Buckling of Thin-Walled C i r c u l a r Cylinders. NASA SP-8007.
(12-5) PETERSON, JAMES P . , and ANDERSON, JAMES KENT

1965. T e s t of a T r u s s - C o r e Sandwich Cylinder Loaded to F a i l u r e
i n Bending. NASA Tech. Note D-3 157.
(12-6) PETERSON, JAMES P . , and ANDERSON, JAMES KENT

1965. S t r u c t u r a l Behavior and Buckling Strength of Honeycomb
Sandwich Cylinders Subjected i o Bending. NASA Tech.
Note D-2926.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(12 -7) STEIN, MANUEL, and MAYERS, J .

1952. C o m p r e s s i v e Buckling of Simply Supported Curved P l a t e s
and Cylinders of Sandwich Construction. NACA T e c h .
Note 2601.
(12-8) U . S ; DEPARTMENT O F DEFENSE

C u r r e n t Metallic M a t e r i a l s and E l e m e n t s f o r A e r o s p a c e Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5. Available f r o m U . S. Gov.
P r i n t i n g Office, Washington, D. C.

1962. Composite Construction f o r Flight Vehicles: P a r t III, Design
P r o c e d u r e s . MIL-HDBK-23, P a r t III.
(12-10) ZAHN, JOHN J., and KUENZI, EDWARD W .

1963. C l a s s i c a l Buckling of Cylinders of Sandwich Construction i n
Axial Compression--0rthotropic C o r e s . U . S. F o r e s t S e r v i c e
R e s e a r c h Note F P L - 0 1 8 . F o r e s t P r o d . L a b . , Madison, W i s .
12-8
__ __-__ c _ -- --- -- . -.--___
.

I
-___ - --
MIL-HBBK-23A CHG N O T I C E 3 E 9 9 9 9 9 7 0 014Bi12Y 593 E
cU
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
y-
$
SI
I Q
ir,
o' 8
-______
-----
~ ~ _ =
-----

MIL-HDBK-23A CHG N O T I C E 3 6 9 9 9 9 9 7 0 0148125 427' 6
c
I --`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
/
b

__ ~
MIL-HDBK-23A CHG N O T I C E 3 M 70 O L 4 8 L 2 b 366
MIL-HDBK-23 A
3 0 Dec 1968
CHAPTER 13
DESIGN O F SANDWICH CYLINDERS
Assuming that a design begins with chosen design s t r e s s e s and given

design loads to t r a n s m i t , a c i r c u l a r cylinder with walls of sandwich con-
s t r u c t i o n s h a l l be designed with t h e four b a s i c design principles s u m m a r i z e d
in s e c t i o n 1.2 of the Introduction. T h e s e four conditions m u s t be m e t .
Facing s t r e s s e s s h a l l be d e t e r m i n e d f o r e a c h load applied s e p a r a t e l y

( s e e a p p r o p r i a t e c h a p t e r s ) and the effects of combining the loads and s t r e s s e s
s h a l l be a s s e s s e d by a p p r o p r i a t e i n t e r a c t i o n f o r m u l a s f o r the facing m a t e r i a l s
as given in r e f e r e n c e s 13-6 and 13-7 w h e r e i n design values f o r t h e s e s t r e s s e s
a r e established.
O v e r a l l buckling of the sandwich walls o r dimpling o r wrinkling of the

facings cannot o c c u r without possible t o t a l collapse of the cylinder. Local
f a i l u r e by wrinkling of the facings under loads o t h e r than uniaxial c o m -
p r e s s i o n a r e not given, and i t i s n e c e s s a r y to d e t e r m i n e this behavior of the
sandwich by testing s m a l l s p e c i m e n s i f e s t i m a t e s b a s e d on information given
i n C h a p t e r 3 show that f a i l u r e by wrinkling of facings could b e expected.
Dimpling of facings u n d e r combined loads i s not given; however, the i n f o r m a -
tion given in Chapter4 c a n be combined with i n t e r a c t i o n f o r m u l a s f o r buckling
of t h e individual facing s h e e t s a s given i n r e f e r e n c e s 13-2 and 13-6 to obtain
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
. s o m e e s t i m a t e s that c a n be confirmed by t e s t s of s m a l l s p e c i m e n s .
O v e r a l l buckling of t h e sandwich walls of cylinders u n d e r combined loads

is given by i n t e r a c t i o n f o r m u l a s i n t e r m s of t h e r a t i o s , R , w h e r e i n R
denotes t h e r a t i o of the applied s t r e s s o r load u n d e r combined loading to the
buckling s t r e s s o r load u n d e r s e p a r a t e loading (R = N / N ). Appropriate
cr
s u b s c r i p t s a r e given to R to denote s t r e s s o r load and direction.
13-1

--_
lIL-HDBK-23A C H G N O T I C E 3 W 9999970 OL48L27 2 T 2 W
13.2 A X I A L C O M P R E S S I O N A N D E X T E R N A L
L A T E R A L PRESSURE
O v e r a l l buckling of the sandwich w a l l s of a c i r c u l a r cylinder u n d e r a x i a l

c o m p r e s s i o n and e x t e r n a l l a t e r a l p r e s s u r e c a n be e s t i m a t e d by the i n t e r -
action f o r m u l a
R t R = 1 (13: 1 )
cx PY
T h i s f o r m u l a is usually somewhat c o n s e r v a t i v e f o r m o s t sandwich c y l i n d e r s .

It c a n b e exceedingly c o n s e r v a t i v e f o r sandn.ich u-ith V > > O . For morc
a c c u r a t e a n a l y s e s , including sandLvich l v a l l s \rith c o r r u g a t e d c o r e , consult
r e f e r e n c e s 1 3 - 1 , 1 3 - 3 , 13-4, and 13-5.
13.3 AXIAL COMPRESSION AND TORSION
O v e r a l l buckling of the sandwich L v a l l s of a c i r c u l a r cy1indt.r u n d e r a x i a l

c o m p r e s s i o n and t o r s i o n c a n b e e s t i m a t e d by the interaction f o r m u l a
R t R = 1 (13:2)
C S
T h i s f o r m u l a is conservative f o r s h o r t and thick-Lvalled cylinders f o r \I hich the

t o r s i o n ( R s ) t e r m should have an exponent of 2 . The f o r m u l a can be v e r y
c o n s e r v a t i v e f o r sandwich with V > > O . F o r m o r e a c c u r a t e a n a l y s i s of s a n d -
wich w a l l s with c o r r u g a t e d c o r e consult r e f e r e n c e s 13-1 and 13-3.
13.4 T O R S I O N A N D L A T E R A L E X T E R S A L OR
INTERNAL PRESSURE
O v e r a l l buckling of the sandLxs-ichn.alls of a c i r c u l a r cylinder u n d e r t o r s i o n

and e x t e r n a l o r i n t e r n a l p r e s s u r e can b e e s t i m a t e d by the interaction f o r m u l a
2
R t R = 1 (13:3)
P S
F o r external pressure R is positive and f o r i n t e r n a l p r e s s u r e R p is negative.

P
Details of the derivation and r e s u l t a n t i n t e r a c t i o n c u r v e s a r e given in
r e f e r e n c e s 13-1 and 13-3.
13 -2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
r
____
MIL-HDBK-23A C H G N O T I C E 3 m 9999970 OL4BL28 1 3 9 W
(13-1) BAKER, E . H.
1964. Stabilitv of C i r c u m f e r e n t i a l l v C o r r u e a t e d Sandu i c h Cvlinders
Under Combined L o a d s . AIAA J o u r n . vol. 2 , N O . 12.
(13-2) GERARD, GEORGE and BECKER, HERBERT

1957. Handbook of S t r u c t u r a l Stability, P a r t III- -Buckling of Curved
P l a t e s and Shells. NACA T e c h . Note 3783.
(13-3) HARRIS, L. A . , a n d B A K E R , E . H.
1962. E l a s t i c Stability of Simply-Supported C o r r u g a t e d - C o r e Sand-
wich C y l i n d e r s . In: Collected P a p e r s on Instability of S h e l l
S t r u c t u r e s . NASA Tech. Note D-1510.
(13-4) MAKI,*A. CARL

1967. E l a s t i c Stability of C y l i n d r i c a l Sandwich S h e l l s Under Axial
and Lateral Load. U.S. F o r e s t S e r v . R e s . Note F P L - 0 1 7 3 .
F o r e s t P r o d . L a b . , Madison, Wis.
(13-5) PLANTEMA, FREDERICK J .

1966. Sandwich Construction. John Wiley and S o n s , Inc.

C u r r e n t P l a s t i c s f o r F l i g h t Vehicles: P a r t I , R e i n f o r c e d P l a s t i c s .
Available f r o m U . S. Gov. P r i n t i n g Office, Washington, D. C.

C u r r e n t M e t a l l i c M a t e r i a l s and E l e m e n t s f o r A e r o s p a c e Vehicle
S t r u c t u r e s . M i l i t a r y Handbook 5 Available f r o m U . S .
Gov. P r i n t i n g Office, Washington, D. C.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
13 - 3
--=----- ----

NIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L 4 L 2 9 075 =
MIL-HDBK-2%
30 Dec 1968
CHAPTER 14
FABRICATION
14.1 FABRICATION O F CORES
14.1.1 PreDaration f o r Use
From the position of the sandwich f a b r i c a t o r , the c o r e a s r e c e i v e d i s a

raw m a t e r i a l , and t h e r e f o r e t h e manufacture of the c o r e s t o c k will not be
c o n s i d e r e d i n this manual. All c o r e m a t e r i a l s d e s c r i b e d in c h a p t e r 2 m u s t
b e p r e p a r e d f o r u s e b y the sandwich f a b r i c a t o r . This p r e p a r a t i o n c o n s i s t s
of machining i n s o m e m a n n e r o r , in isolated c a s e s , of mixing, pouring, o r
expanding t h e r a w m a t e r i a l s . S o m e of the m o r e c o m m o n m e a n s of p r e p a r -
ing c o r e m a t e r i a l s f o r u s e in sandwich s t r u c t u r e s a r e p r e s e n t e d h e r e .
14.1.1.1 Aluminum Honeycomb
Aluminum honeycomb is r e c e i v e d in t h e f o r m of blocks o r in s l i c e s cut

to p r o p e r t h i c k n e s s e s . T h e s e c o r e blocks can b e s l i c e d on a metal-cutting
bandsaw. High cutting s p e e d s and fine-tooth blades a r e d e s i r a b l e f o r b e s t
r e s u l t s (fig. 14-1). Dimensional t o l e r a n c e s a r e n o r m a l l y held to *O. 0 0 5
inch.
F o r sawing expanded honeycomb b l o c k s , a s p e c i a l honeycomb cutting

blade has been developed. W i t h this honeycomb cutting blade, v e r y zood
s u r f a c e finishes c a n b e achieved. The optimum speeds of the blade and
feeding v a r y with c e l l s i z e and foil gage combinations.
Specially designed contouring machines s u c h a s the horizontal bandsaw

shown i n f i g u r e 14-2 a r e s o m e t i m e s u s e d for quantity production of con-
t o u r e d c o r e s of aluminum honeycomb. Compound contouring i s e a s i l y p e r -
f o r m e d with p r o p e r tooling.
14-1
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c ___ -
Aluminum honeycomb c o r e s m u s t often be routed a t specific locations

f o r doublers. This operation i s n o r m a l l y p e r f o r m e d using a high-speed
t r a v e l i n g bed r o u t e r , with a c u t t e r usually r e f e r r e d to a s a "valve s t e m "
c u t t e r . An operation of this type and s o m e typical c u t t e r s a r e shown in
f i g u r e 14-3. S o m e t i m e s the c u t t e r i s shielded with a "chipper, which
b r e a k s u p the w a s t e (the m a t e r i a l removed) into chips f o r convenient
r e m o v a l . By modifying the details of the cutter and the chipper, the s a m e
p r o c e d u r e c a n be u s e d f o r cutting s t a i n l e s s s t e e l honeycomb, o r for contour-
ing m e t a l honeycomb c o r e s .
P r e c u t blocks of honeycomb c o r e , r e a d y for u s e i n a n a s s e m b l y , should

b e handled with e x t r e m e c a r e to avoid contamination. The u s e of clean white
cotton gloves and r e u s a b l e containers t o p r o t e c t the delicate p r e c u t c o r e s ,
as shown i n f i g u r e 14-4, is recommended.
oc
14.1. i. 2 S t a i n l e s s S t e e l Honeycomb
When r e q u i r e d , s t a i n l e s s s t e e l honeycomb c o r e can b e rough cut to a

t o l e r a n c e of *O. 006 to O. 010 inch by f r i c t i o n hand sawing. F o r final finish-
ing t o c l o s e t o l e r a n c e s , e i t h e r e l e c t r o l y t i c surfacing o r disk cutting a r e
m o s t commonly used.
E l e c t r o l y t i c surfacing (fig. 14-5) is a method of e l e c t r i c a l - d i s c h a r g e

grinding t h a t combines two methods of m e t a l r e m o v a l - - s p a r k e r o s i o n and
m e c h a n i c a l abrasion. A p r o c e s s u s e d to advantage f o r s u r f a c i n g s t a i n l e s s
s t e e l honeycomb c o r e involves utilization of an e l e c t r o l y t e a s a d i e l e c t r i c
and coolant in combination w i t h e l e c t r i c a l c i r c u i t r y , which includes the
honeycomb c o r e a s the anode and the e l e c t r o l y t i c g r i n d e r a s the cathode.
The c u t t e r is a conductor with a random d i s p e r s i o n of a r e s i n - b o n d e d a b r a -
s i v e nonconductor on the working s u r f a c e . The s u r f a c i n g operation i s
a c c o m p l i s h e d by rotating the c u t t e r cathode while gradually advancing i t
a c r o s s the s u r f a c e of the honeycomb. As the wheel r o t a t e s , a l t e r n a t e l y a
conducting a r e a and a nonconductive a b r a s i v e a r e a contacts the c o r e m a t e -
rial, t h e r e b y c r e a t i n g a s p a r k t h a t b r e a k s down the e l e c t r o l y t e and d i s -
lodges m e t a l f r o m the honeycomb s u r f a c e . The m e t a l in t u r n is washed away
by the flow of e l e c t r o l y t e . The nonconductive a b r a s i v e in the cutting wheel
m a i n t a i n s the s p a r k gap and m a k e s and b r e a k s the c u r r e n t .
In disk cutting, disk, v a l v e - s t e m , o r "baloney-slicer" c u t t e r s , equipped

with f e a t h e r edges of Stellite o r o t h e r h a r d facing m a t e r i a l , have been
developed that will cut s t a i n l e s s c o r e b u r r - f r e e t o t o l e r a n c e s of I0.002 inch.
U s u a l p r o c e d u r e when t h i s equipment i s u s e d i s t o take a s e r i e s of t.hin cuts
until the r e q u i s i t e amount of m a t e r i a l has b e e n r e m o v e d . Stabilization of
the c o r e m a t e r i a l , e i t h e r by filling the c e l l s with w a t e r and f r e e z i n g to a
r e f r i g e r a t e d platen, o r filling with s o m e o t h e r m a t e r i a l s u c h a s p l a s t i c f o a m , -
polyethylene glycol, o r o t h e r w a t e r - s o l u b l e compound, i s p r a c t i c a l l y e s s e n -
tial when t h i s technique is used.
-----------_ - 14-2
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On s u r f a c e s t h a t a r e adequately stabilized, s u r f a c e grinding tools coated
with s p e c i a l a b r a s i v e s a l s o have been u s e d s u c c e s s f u l l y to produce an a c c e p t -
a b l e s u r f a c e f r e e of b u r r i n g o r layover.
Another technique f o r finishing s t a i n l e s s c o r e i s t h e Elox e l e c t r i c a l

method. In this r e l a t i v e l y slow but v e r y a c c u r a t e p r o c e s s , the c o r e m a t e -
rial is e r o d e d to the d e s i r e d thickness b y s p a r k i n g o r burning.
14.1.1.3 G l a s s - F a b r i c Honeycomb
Blocks of g l a s s - f a b r i c honeycomb c o r e m a t e r i a l m a y be cut to finished

thickness on a bandsaw. A v a r i e t y of metal-cutting bandsaw b l a d e s , r u n -
ning at s p e e d s f r o m 1 , 5 0 0 to 9 , 0 0 0 f e e t p e r minute, have been found to give
s a t i s f a c t o r y r e s u l t s . The fabrication application m a y r e q u i r e a long fiber
being exposed a f t e r cut, which can b e achieved with a four-tooth blade r u n -
ning f o r w a r d at about 4 , 5 0 0 f e e t p e r minute. A v e r y smooth cut can be
achieved with a six-tooth bandsaw blade running backward a t 5, 500 feet p e r
minute. Slight v a r i a t i o n s i n t h e s e blades o r speeds m a y be n e c e s s a r y f o r
p a r t i c h a r c e l l s i z e s and densities. T h e optimum cutting conditions can
probably b e s t b e achieved by trial and e r r o r f o r the specific application.
Thickness t o l e r a n c e s of *0.005 inch should be maintained (fig. 14-6). The
slightly fuzzy c h a r a c t e r of the sawn s u r f a c e i s shown in figure 14-7.
P r e c a u t i o n s m u s t be taken to r e m o v e the fine r e s i n and g l a s s dust that

r e s u l t s f r o m the sawing operation. Dust r e m o v a l m a y be accomplished by
drilling holes in the fence n e a r the saw and applying suction to the f a r side
t o draw u p the dust, as shown i n f i g u r e 14-8. In addition, a n adequate r e s -
p i r a t o r o r dust f i l t e r should be w o r n by the o p e r a t o r when l a r g e quantities
are cut.
F o r convenience in handling when l a r g e f l a t p a r t s a r e being f a b r i c a t e d ,

the s l i c e s of g l a s s - f a b r i c honeycomb c o r e m a y be edge bonded in the u s u a l
I m a n n e r by hand p r e s s u r e and the glue c u r e d by high-frequency d i e l e c t r i c
heating. G l a s s - f a b r i c honeycomb is u s e d f o r radome applications and t h e r e -
f o r e must be t a i l o r e d v e r y carefully to f i t the c u r v a t u r e of the mold. This
r e q u i r e s s m a l l e r p i e c e s , which a r e cut f r o m the sawn s l i c e s .
14-3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Provided by IHS
f
--
HIL-FDK-23A CHG N O T I C E 3 W 9999770 0 3 4 8 3 3 2 bbT
T y p i c a l joints between individual p i e c e s of glas s - f a b r i c honeycomb c o r e

a r e shown in f i g u r e 14-9. F o r m a x i m u m s t r e n g t h the i n t e r l o c k type of joint
is p r e f e r r e d . M o s t types of g l a s s - f a b r i c honeycomb will i n t e r l o c k v e r y
u n i f o r m l y if they a r e o v e r l a p p e d about one c e l l d i a m e t e r and c r u s h e d into
e a c h o t h e r by m e a n s of a m a l l e t o r a c o m p r e s s i o n block, Tightly fitted butt
joints u s u a l l y give adequate s t r e n g t h p r o p e r t i e s , p a r t i c u l a r l y i f they a r e
bonded together s o as to develop a high p e r c e n t a g e of the s h e a r s t r e n g t h of
the unjointed c o r e m a t e r i a l . Open butt joints are g e n e r a l l y not allowed for
s t r u c t u r a l p a r t s ; they a r e p e r m i s s i b l e only when s t r e s s e s a r e low, and
facings a r e thick enough to c a r r y the s h e a r .
G l a s e - f a b r i c p l a s t i c honeycomb of the f o r m i n g g r a d e c a n b e p r e f o r m e d
to s i m p l e o r compound c u r v a t u r e s by heating and molding in the p r o p e r
r a d i u s . S o m e of the honeycomb m a n u f a c t u r e r s s p e c i a l i z e in supplying p r e -
f o r m e d honeycomb c o r e s .
I m m e d i a t e l y b e f o r e u s e , t h e p i e c e s of g l a s s - f a b r i c honeycomb c o r e a r e
s o m e t i m e s t r e a t e d with t h e s a m e r e s i n t h a t i s to b e u s e d in the facings. The
p i e c e s m a y b e dipped in a thin solution ( n o r m a l l y about 2 0 p e r c e n t ) of the
r e s i n in a c e t o n e and u s e d as soon as the acetone h a s e v a p o r a t e d , o r unthinned
r e s i n m a y b e r o l l e r - c o a t e d on the s u r f a c e s . E i t h e r methQd supplies addi-
tional r e s i n at the i n t e r f a c e between the c o r e and t h e f a c i n g s , and thus p r o -
v i d e s i n c r e a s e d bond s t r e n g t h and, in addition, a tacky s u r f a c e that aids in
laying u p complicated s h a p e s .
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14.1.1.4 Foamed-in-Place Cores
F o a m e d - i n - p l a c e c o r e m a t e r i a l s a r e b a s e d upon the r e a c t i o n of an
u n s a t u r a t e d alkyd r e s i n with an i s o c y a n a t e , r e s u l t i n g in the liberation of
c a r b o n dioxide gas. The r e a c t i o n is e x o t h e r m i c and the m i x t u r e m u s t be
c o n t r o l l e d within a t e m p e r a t u r e range of 7 5 " t o 8 5 " F. If the t e m p e r a t u r e
e x c e e d s 8 5 " F , the r e a c t i o n will proceed to completion without c o n t r o l on
the quality of foam produced. The r e s i n and isocyanate a r e not r e a d i l y
m i s c i b l e and r e q u i r e about one-half hour to m i x thoroughly, The o t h e r two
component s y s t e m s f u r n i s h e d by s e v e r a l s u p p l i e r s a r e r e a d i l y m i s c i b l e and
r e q u i r e somewhat l e s s t i m e for mixing to a homogeneous blend. B e c a u s e
of the n a t u r e of the compounds u s e d , the mixing equipment should be placed
u n d e r a hood, and w o r k e r s should be p r o t e c t e d by gloves and f r e s h - a i r
hoods. When the liquid i s thoroughly m i x e d , the liquid i s poured into the
mold and heated to the d e s i r e d t e m p e r a t u r e until expansion c e a s e s . T e m -
p e r a t u r e s varying f r o m room t e m p e r a t u r e to 2 0 0 " F have been u s e d f o r
t h i s step. A f t e r expansion c e a s e s , the c o r e m a t e r i a l is given a final c u r e
f o r about 2 h o u r s at a slightly h i g h e r t e m p e r a t u r e .
14-4

- ____-- - - - --
-
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 0348333 5Tb
14. 1.1.5 L o s t Wax P r o c e s s
A technique s o m e t i m e s r e f e r r e d to a s the l o s t wax p r o c e s s , h a s found

application f o r producing a s p e c i a l type of c o r e through which hot air can be
fed f o r de-icing p u r p o s e s . This type of construction is s o m e t i m e s u s e d as
a c a p o v e r the portion of a r a d o m e , o r m a y be u s e d (if p r o p e r l y constructed)
a s a self de-icing sandwich. E x t r u d e d b a r s of a specially p r e p a r e d wax
formulation a r e helically wrapped with a ribbon of g l a s s f a b r i c as shown in
f i g u r e 14-10. T h e s e wrapped extruded b a r s a r e somewhat flexible and can
be f o r m e d to the d e s i r e d shape and e n c a s e d within g l a s s - f a b r i c f a c i n g s . A
s e c t i o n f r o m a typical sandwich p a r t m a d e by the l o s t wax p r o c e s s is shown
i n f i g u r e 14-1 1. After the p a r t is p a r t i a l l y c u r e d a t a carefully controlled
t e m p e r a t u r e (slightly below the melting point of the s p e c i a l wax), the t e m -
p e r a t u r e is r a i s e d to allow the s p e c i a l wax to m e l t and run out. The p a r t i s
then c u r e d a t a higher t e m p e r a t u r e to produce optimum s t r e n g t h p r o p e r t i e s .
The wax is then r e u s e d in the extrusion machine.
14. 1.1.6 Balsa
Two methods of c o r e p r e p a r a t i o n a r e in u s e f o r balsa: ( i ) Bandsawing

e n d - g r a i n s l a b s f r o m l a r g e bonded billets and sanding to finished t h i c k n e s s ,
o r (2) sawing e n d - g r a i n s l a b s to finished thickness f r o m planks, followed
by edge bonding to the p r o p e r c o r e s i z e . Both methods r e q u i r e that the
s e l e c t e d b a l s a planks be a c c u r a t e l y jointed and planed to a r e c t a n g u l a r o r
s q u a r e c r o s s section. Conventional woodworking m a c h i n e r y , s u c h a s a
j o i n t e r , r i p s a w , and cabinet p l a n e r , m a y be used.
14.1.1.7 P a p e r Honeycomb
The s m a l l - c e l l type with high r e s i n content can be sawed on a c i r c u l a r

saw into smoothly cut s l a b s having thickness t o l e r a n c e s of IO. 008 inch i f
the block is l e s s than 3 inches thick. It m a y a l s o be cut on a bandsaw into
s l i c e s having slightly roughened s u r f a c e s and somewhat l a r g e r t o l e r a n c e s .
The l a r g e - c e l l type with low r e s i n content i s usually cut on a bandsaw.
14.2 FABRICATION O F BONDED CONSTRUCTION
In bonding sandwich c o n s t r u c t i o n , including bonds between . m e t a l facings

and the m e t a l fittings, reinforcing p l a t e s , and o t h e r i n s e r t s , carefully con-
t r o l l e d fabrication techniques a r e r e q u i r e d in using r e s i n a d h e s i v e s .
14-5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~ - - _ _ _ - ._
MIL-HDBK-23A C H G N O T I C E 3 W 9999970 0348334 432
14.2.1 P r e p a r a t i o n f o r Bondine:
T h i s s e c t i o n outlines the g e n e r a l methods of p r e p a r i n g the m e t a l facings

f o r bonding, and the g e n e r a l f a b r i c a t i o n p r o c e d u r e s u s e d in bonding the sand-
wich -components together with r e s i n adhesives.
14.2. 1. 1 S u r f a c e P r e p a r a t i o n of M e t a l s f o r Bonding
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
It is e s s e n t i a l i n good bonding p r a c t i c e that g r e a s e s , w a x e s , o i l s , loose

o x i d e s , and o t h e r contaminants b e removed f r o m the m e t a l s u r f a c e s , and
t h e s u r f a c e then kept c l e a n until the adhesives a r e applied. Metal p r e p a r a -
tion f o r bonding is now thought to be m o r e than m e r e l y cleaning the s u r f a c e .
It is known that the c h e m i c a l n a t u r e of the m e t a l s u r f a c e at the t i m e of bond-
ing influences not only the initial d e g r e e of adhesion, but probably a l s o the
p e r m a n e n c e of the bonds ( p a r t i c u l a r l y at elevated t e m p e r a t u r e s i n s e r v i c e )
and the p e r m a n e n c e of the m e t a l itself u n d e r c o r r o s i v e conditions. With
s o m e m e t a l s , etching of the s u r f a c e s p r i o r to application of the adhesive
h a s been found e s s e n t i a l to obtain the highest quality bonds. With o t h e r
m e t a l s that c o r r o d e e a s i l y , s p e c i a l protective coatings m u s t be applied to
the s u r f a c e s p r i o r to bonding when it is difficult to apply t h e s e protective
t r e a t m e n t s to the p a r t s after fabrication. S e v e r a l extensive r e p o r t s ( r e f .
14-3, 14-5, and 14-9) have been p r e p a r e d on investigations of s u r f a c e t r e a t -
m e n t s f o r m e t a l s p r i o r to bonding. Adhesive s u p p l i e r s usually specify p r o -
c e d u r e s f o r p r e p a r a t i o n of v a r i o u s m e t a l s u r f a c e s f o r bonding with t h e i r
adhesives.
In the u s e of the v a r i o u s c h e m i c a l solutions, p a r t i c u l a r l y alkaline s o l u -

t i o n s , c a r e should be taken t h a t t h e s e solutions do not d r y on the s h e e t s , a s
they a r e often difficult to remove when d r y . T h e final t r e a t m e n t of an a l u m i -
n u m s u r f a c e should n e v e r be done with an alkaline solution, and when a l k a -
line solutions a r e u s e d in d e g r e a s i n g , a c h r o m i c acid o r s i m i l a r acid s o l u -
tion m u s t be u s e d as the final t r e a t m e n t . A thorough rinsing of a l l c h e m i c a l
solutions f r o m the s h e e t s is n o r m a l l y r e q u i r e d in o r d e r to obtain optimum
bonding r e s u l t s . It is likewise v e r y i m p o r t a n t that cleaned m e t a l s u r f a c e s
be handled c a r e f u l l y to avoid f u r t h e r contamination before the adhesive i s
applied. G e n e r a l l y adhesives should be applied a s soon a f t e r the m e t a l h a s
b e e n p r e p a r e d as is p r a c t i c a l .
1 4 . 2 . 1 . 1 . 1 S u r f a c e P r e D a r a t i o n of C o r e s . - - C e l l u l a r aluminum c o r e
m a t e r i a l s with adhesive-bonded nodes and s i m i l a r s t a i n l e s s s t e e l c o r e m a t e -
rials with adhesive-bonded o r spot-welded nodes should r e c e i v e c a r e f u l s u r -
f a c e p r e p a r a t i o n b e f o r e being bonded o r b r a z e d to facings to f o r m sandwich
c o n s t r u c t i o n s . All c o r e m a t e r i a l s , a f t e r being cut o r o t h e r w i s e f o r m e d into
t h e d e s i r e d s i z e , s h a p e , o r contour, should r e c e i v e a d e g r e a s e t r e a t m e n t .
A suitable method is liquid o r v a p o r i m m e r s i o n i n s t a b i l i z e d t r i c h l o r o e t h y l e n e .
T h i s m a y be followed by a c h e m i c a l t r e a t m e n t .
14-6

~ _ _ _ _ _ _
MIL-HDBK-23A CHG N O T I C E 3 9999970 OL48L35 379
C h e m i c a l t r e a t m e n t s a r e somewhat specific f o r types of s t e e l c o r e u s e d .

S a t i s f a c t o r y t r e a t m e n t s u s e d f o r s h e e t s t e e l - t o - s t e e l bonds m a y b e used f o r
s t e e l c o r e materials b e c a u s e they do not etch and remove m e t a l a s f a s t as
do etch t r e a t m e n t s f o r aluminum alloys. C e r t a i n t r e a t m e n t s with mild
d e t e r g e n t and s t r o n g acid a r e suitable and a r e s u m m a r i z e d under s u r f a c e
p r e p a r a t i o n of m e t a l s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
14.2.1.2 Inspection of T r e a t e d M e t a l S u r f a c e s
To d e t e r m i n e i f a metal s u r f a c e h a s been sufficiently cleaned of g r e a s e s ,

w a x e s , and o i l s to be bonded, many f a b r i c a t o r s u s e the w a t e r - f i l m t e s t .
T h i s test c o n s i s t s of running cold w a t e r o v e r the s u r f a c e , allowing the
e x c e s s w a t e r to run off, and then inspecting the s u r f a c e s for a r e a s xxhhcrc. thc
w a t e r film b r e a k s due to the p r e s e n c e of g r e a s e s , o i l s , and waxes (fig. 14-12).
P o r t a b l e i n s t r u m e n t s have a l s o been developed f o r u s e in determining con-
t a c t angles between the w a t e r d r o p and m e t a l s u r f a c e . S u r f a c e s that show.
areas with s u c h b r e a k s i n the w a t e r film o r high contact angles should be
r e c l e a n e d before bonding.
Since m e t a l p r e p a r a t i o n r e q u i r e s t r e a t m e n t s other than s i m p l e d e g r e a s -

ing, it cannot be a s s u m e d that m e t a l s u r f a c e s will be s a t i s f a c t o r y f o r bonding
i f t h e r e a r e no a r e a s that show w a t e r b r e a k s in the w a t e r - f i l m t e s t . T h e r e
h a s b e e n s o m e evidence t h a t poor adhesion h a s been obtained to "nonbreak"
s u r f a c e s b e c a u s e of thin f i l m s o r s t a i n s f r o m the cleaning solutions, loose
o x i d e s , o r p a r t i c l e s on the s u r f a c e o r t h a t the m e t a l m a y r e q u i r e an etching
of t h e s u r f a c e in addition to being f r e e of i m p u r i t i e s .
1 4 . 2 . 1 . 3 Handling and S t o r a g e of T r e a t e d
Metal Surfaces
A f t e r m e t a l s u r f a c e s have been p r e p a r e d f o r bonding, they should not be

handled with b a r e hands o r placed in contact with o t h e r contaminating s o u r c e s
i n any subsequent operation until the final bonding h a s been completed.
Clean, white cotton gloves should be u s e d a s p r e s c r i b e d in M i l i t a r y Specifi-
c a t i o n MIL-A-9067 ( r e f . 14-10). After p r o p e r s u r f a c e t r e a t m e n t h a s been
m a d e , no longer than one 8-hour shift s h a l l e l a p s e before bonding, u n l e s s
an approved p r i m e d s u r f a c e h a s been applied. Even if s u c h approved p r i m e
s y s t e m s a r e u s e d , t e s t s should be conducted by the f a b r i c a t o r to d e t e r m i n e
the m a x i m u m allowable period of s t o r a g e .
14 -7
------ -'
~ --

14.2.1.4 Aluminum S u r f a c e P r e p a r a t i o n
As much of the adhesive bonding of m e t a l s has.involved the u s e of clad

aluminum alloy, s u r f a c e p r e p a r a t i o n methods f o r t h i s m e t a l have become
m o r e s t a n d a r d i z e d than for the o t h e r m e t a l s . It i s the g e n e r a l p r a c t i c e to
wipe the aluminum s h e e t s with a clean cloth s a t u r a t e d with a solvent s u c h a s
acetone, naphtha, toluene, o r l a c q u e r thinner to partially r e m o v e identifica-
tion m a r k i n g s . T h e s e s h e e t s m a y then be vapor d e g r e a s e d in t r i c h l o r o e t h y l -
ene vapor d e g r e a s e r . After the v a p o r d e g r e a s i n g , the s h e e t s a r e etched in
s u l f u r i c a c i d - s o d i u m d i c h r o m a t e solution, rinsed in w a r m - w a t e r s p r a y , and
then d r i e d . M i l i t a r y Specification MIL-A-9067 ( r e f , 14- 10) suggests that
aluminum f o r bonding be d e g r e a s e d with organic solvent and then i m m e r s e d
f o r 10 m i n u t e s a t 150" t o 160" F. in a solution of:
1 p a r t by weight of sodium d i c h r o m a t e
10 p a r t s by weight c o n c e n t r a t e d s u l f u r i c acid (specific gravity 1.84)
30 p a r t s w a t e r by weight
The aluminum i s r i n s e d in w a t e r and then a i r - d r i e d f o r 3 0 m i n u t e s .

O t h e r methods a r e to be u s e d only when approved by the p r o c u r i n g agency.
Some modifications and s p e c i a l precautions have b e e n adopted by f a b r i -

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
c a t o r s using t h e s e g e n e r a l cleaning methods. A hot alkaline s o d i u m -

m e t a s i l i c a t e cleaning and w a r m - w a t e r r i n s e i s u s e d by s o m e f a b r i c a t o r s ,
in place of, o r in addition t o , the vapor d e g r e a s i n g method. O t h e r f a b r i c a -
t o r s have i n c r e a s e d the r a t i o of sodium d i c h r o m a t e to s u l f u r i c acid in the
e t c h solution in o r d e r to i n c r e a s e the useful life of this solution. Also s o m e
s t r u c t u r a l a d h e s i v e s produce b e t t e r and m o r e p e r m a n e n t bonds with higher
concentrations of sodium d i c h r o m a t e . T h e u s e of the higher concentration
of sodium d i c h r o m a t e , which i s n o r m a l l y c o n s i d e r e d t o have inhibiting action
i n the solution m a y r e s u l t , h o w e v e r , in l e s s etching i f the s a m e t i m e and
t e m p e r a t u r e a r e u s e d with the solution. Sulfuric a c i d - c h r o m i c acid s o l u -
tions having s i m i l a r composition t o the s u l f u r i c a c i d - s o d i u m d i c h r o m a t e
solution have a l s o been u s e d f o r p r e p a r i n g aluminum s u r f a c e s f o r bonding.
The s p r a y r i n s e i s c o n s i d e r e d t o be i m p o r t a n t i n obtaining optimum

r e s u l t s with the s u l f u r i c a c i d - d i c h r o m a t e e t c h t r e a t m e n t . P r e c a u t i o n s a r e
t a k e n by s o m e f a b r i c a t o r s in a r e a s w h e r e t a p w a t e r h a s high m i n e r a l con-
t e n t to u s e s t e a m condensate o r deionized w a t e r f o r the r i n s e . The t e m p e r -
a t u r e of this r i n s e w a t e r is usually controlled a t l e s s than 150" F a s t h e r e
a r e indications that higher t e m p e r a t u r e w a t e r m a y r e s u l t in sealing of the
e t c h e d s u r f a c e t o produce an u n d e s i r a b l e h y d r a t e d oxide and t h e r e f o r e r e s u l t
in low bonding c h a r a c t e r i s t i c s .
14 -8

= 9999970 0348337 =
~
MIL-HDBK-23A CHG NOTICE 3 343
O t h e r types of s u r f a c e p r e p a r a t i o n f o r aluminum a r e a l s o u s e d in special

applications. B a r e aluminum alloys given c h r o m i c acid o r s u l f u r i c acid
anodizing t r e a t m e n t s c a n be bonded, but sealing t r e a t m e n t s f o r these anod-
ized coatings to protect the m e t a l s t h e m s e l v e s should be done a f t e r bonding
b e c a u s e s u c h s e a l t r e a t m e n t s p r i o r to bonding g r e a t l y reduce the s t r e n g t h of
bonds ( r e f . 14-3) that c a n be obtained to t h e s e s u r f a c e s . Bonding m u s t be
done in s o m e instances to s u r f a c e s that have been t r e a t e d by p r o p r i e t a r y
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
s u r f a c e t r e a t m e n t s approved f o r s u r f a c e s in contact with a i r c r a f t fuels.
Strength of bonds obtained to t h e s e s u r f a c e s a r e not usually a s high a s those
obtained to aluminum s u r f a c e s p r e p a r e d with the s u l f u r i c acid- sodium
d i c h r o m a t e solution, but m a y be c o n s i d e r e d s a t i s f a c t o r y .
T h e r e a r e applications where it i s not p r a c t i c a l to u s e hot sodium

d i c h r o m a t e - s u l f u r i c solution f o r p r e p a r i n g the aluminum s u r f a c e s u c h a s
f o r s e c o n d a r y bonding to p a r t s a l r e a d y containing adhesive bonds, and f o r
r e p a i r of a s s e m b l e d p a r t s , Solvent cleaning o r washing with w a r m alkaline
cleaning solutions, followed by m i l d acid neutralizing, m a y be sufficient i n
such c a s e s .
High-strength bonds have a l s o been m a d e to m e t a l s u r f a c e s p r e p a r e d

with "mild" s u r f a c e t r e a t m e n t s utilizing d e t e r g e n t s or wetting a g e n t s . Con-
s i d e r a b l e experimentation should be done by e a c h f a b r i c a t o r p r i o r to the u s e
of t h e s e t r e a t m e n t s in production. In g e n e r a l , d e t e r g e n t s of the nonionic
type should be u s e d on aluminum alloys and anionic type should be used on
s t a i n l e s s s t e e l . F u r t h e r m o r e , only c e r t a i n d e t e r g e n t s within t h e s e types
a r e effective. Mild d e t e r g e n t m e t a l t r e a t m e n t s a r e p a r t i c u l a r l y adapted t o
m e t a l honeycomb c o r e s . Strong acid s u r f a c e t r e a t m e n t s reduce foil thick-
n e s s and m a y damage the node -to-node bonds.
One specific d e t e r g e n t cleaning method i s : 92. 5 p e r c e n t by weight of

w a t e r , 1. O p e r c e n t by weight of concentrated s u l f u r i c a c i d , 6. O p e r c e n t by
weight of sodium d i c h r o m a t e , and O. 1 p e r c e n t c o m m e r c i a l wetting agent of
the nonionic type, P l u r o n i c F-68 o r equivalent.
Abrading of t h e s u r f a c e s with aluminum wool o r i r o n - f r e e a b r a s i v e cloth

is u s e d i n r e p a i r w o r k and f o r removing c o r r o d e d a r e a s f r o m s h e e t s p r i o r
to r e g u l a r cleaning. C a r e should be taken that the a b r a s i v e s do not include
o t h e r m e t a l s , s u c h as i r o n , that a r e likely to s e t u p e l e c t r o l y t i c f o r c e s
l a t e r to c a u s e c o r r o s i o n of the s h e e t . C h r o m a t e compounds, usually b a s e d
on c h r o m i c and phosphoric acid, and c e r t a i n o t h e r p r o p r i e t a r y compounds
have a l s o been u s e d a t r o o m t e m p e r a t u r e s in p r e p a r i n g the aluminum s u r -
f a c e s f o r bonding when the w a r m sodium d i c h r o m a t e - s u l f u r i c acid solutions
cannot be used. In r e p a i r w o r k , w h e r e c a r e m u s t be taken to prevent the
solutions f r o m getting down into the p a n e l s , p a s t e s m a d e of acid solutions
can be u s e d . T h e s e acid p a s t e s m a y b e p r e p a r e d of cold m i x t u r e s of sodium
d i c h r o m a t e - s u l f u r i c acid solution with i n e r t powders and f i b e r s u c h a s
b a r i u m s u l f a t e , p o t t e r s c l a y , v e r m i c u l i t e , a s b e s t o s f i b e r s , and ground g l a s s
f i b e r s . Any r e s i d u e m u s t be washed and r i n s e d off the panel l a t e r .
14 -9 _ ~ - --
--
-
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 OL4L38 O88
14.2.1.5 Magnesium S u r f a c e P r e p a r a t i o n
Magnesium s u r f a c e s a r e e a s i l y c o r r o d e d , and t h e r e f o r e in applications

f o r a i r f r a m e s t h e s e s u r f a c e s a r e usually p r e p a r e d f o r paint coatings by
c h e m i c a l s e a l methods s u c h a s a r e d e s c r i b e d in M i l i t a r y Specification
MIL-M-3171 ( r e f . 14-11), and by anodize coatings ( r e f . 14-2) and then
c o a t e d with zinc c h r o m a t e paints s u c h a s a r e p r e s c r i b e d i n MIL-P-8585
( r e f . 14-12).
Much of the e x p e r i e n c e in adhesive bonding to m a g n e s i u m has been with

s u r f a c e s t r e a t e d by the methods p r e s c r i b e d i n MIL-M-3 17 1 , Type I
( C h r o m e P i c k l e T r e a t m e n t ) and Type III ( D i c h r o m a t e T r e a t m e n t ) o r anodize
m e t h o d s u s e d in combination with, a zinc c h r o m a t e p r i m e coat before bond-
ing. Bond s t r e n g t h s to s u c h a p r i m e d s u r f a c e have always b e e n lower with
s t a n d a r d high-strength adhesives ( 1 , P O O to 2 , 4 0 0 pounds p e r s q u a r e inch on
1 / 2 - i n c h l a p joint of O. 064-inch thick m e t a l ) , than i s usually obtained in
bonds t o aluminum. I t i s , however, possible to design the bonds to c o m -
p e n s a t e f o r this lower s t r e n g t h . Bonding to m a g n e s i u m with these t r e a t m e n t s
c a n usually b e i m p r o v e d by lighter application of the m e t a l t r e a t m e n t s and of
the p r i m e c o a t , and by baking the p r i m e coat p r i o r to bonding. Additional
protective coats can then be applied a f t e r bonding.
Exceptionally u n i f o r m bonding to m a g n e s i u m alloys , including good p e r -

f o r m a n c e in high humidity and s a l t - w a t e r s p r a y conditions , h a s been obtained
in s t u d i e s ( r e f . 14-4) when using a light acid anodize t r e a t m e n t . Bonding i s
then d i r e c t l y to this anodize coating, with any protective c h r o m a t e p r i m e r s
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
applied a f t e r bonding. The b e s t p e r f o r m a n c e to this anodize coating has
g e n e r a l l y been obtained with flexible a d h e s i v e s of the a c r y l o n i t r i l e -modified
phenolic type.
14.2. 1.6 Stainless Steel Surface Preparation
S a t i s f a c t o r y adhesive bonding can be a c c o m p l i s h e d to many s t a i n l e s s

s t e e l s u r f a c e s by m e r e l y d e g r e a s i n g . However, f o r b e s t p e r f o r m a n c e when
bonds a r e to be exposed t o elevated t e m p e r a t u r e s , c h e m i c a l t r e a t m e n t s a r e
a l s o u s e d in p r e p a r i n g t h e s t a i n l e s s s t e e l s u r f a c e s . S e v e r a l methods have
been u s e d in etching s t a i n l e s s s t e e l f o r bonding. One method c o n s i s t s of
etching f o r 10 m i n u t e s at 140" to 150" F in a solution by weight of:
50 parts of c o n c e n t r a t e d h y d r o c h l o r i c acid (specific gravity 1. 1 9 ) ,

2 parts of 30 p e r c e n t hydrogen peroxide,
10 parts of 40 p e r c e n t f o r m a l i n solution, and
45 parts water
14- 10

After a w a t e r r i n s e , the s t a i n l e s s s t e e l is i m m e r s e d f o r 5 minutes a t
140" to 150" F in the s u l f u r i c acid-sodium d i c h r o m a t e solution, (such a s i s
u s e d f o r etching aluminum) t o r e m o v e the light "smut" f o r m e d during etching.
O t h e r a l t e r n a t i v e methods include: (1) T r e a t m e n t f o r 15 minutes a t

120" F i n a solution composed of:
35 m i l l i l i t e r s of sodium d i c h r o m a t e solution ( s a t u r a t e d a t r o o m t e m p e r -
ature)
1 l i t e r of concentrated sulfuric acid (specific g r a v i t y 1.84)
(2) e t c h f o r 10 minutes at 150" F i n a solution of:
10 p e r c e n t by volume concentrated s u l f u r i c acid (specific gravity 1.84)

O. 5 p e r c e n t of a c o m m e r c i a l liquid wetting agent of the anionic type,
T r i t o n X 2 0 0 o r equivalent
89.5 p e r c e n t w a t e r
w a t e r r i n s e and then i m m e r s e f o r 10 minutes a t r o o m t e m p e r a t u r e in a

solution of:
10 p e r c e n t by volume of concentrated n i t r i c acid (specific gravity 1.42)

2 p e r c e n t by volume of concentrated hydrofluoric acid (60 percent)
88 p e r c e n t w a t e r
o r (3) etch f o r 2 minutes f r o m 180" to 2 0 0 " F i n a solution of:
841 milliliters of hydrochloric acid (specific g r a v i t y 1. 19)

89 m i l l i l i t e r s of phosphoric acid (specific g r a v i t y 1.69)
49 m i l l i l i t e r s of hydrofluoric acid (60 p e r c e n t ) .
Adequate w a t e r rinsing and drying should follow each of t h e s e methods.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Vapor blasting h a s been u s e d s u c c e s s f u l l y in p r e p a r i n g s t a i n l e s s s t e e l
s u r f a c e s , p a r t i c u l a r l y i n t h e fabrication of helicopter blades. C a r e m u s t
be taken, however, t h a t the a b r a s i v e m a t e r i a l s do not contaminate the s u r -
f a c e s being t r e a t e d . It is r e c o m m e n d e d when possible that suitable c h e m -
i c a l t r e a t m e n t s , as l i s t e d above, be u s e d following the vapor b l a s t t r e a t m e n t .
D r y sandblasting is not r e c o m m e n d e d b e c a u s e it d i s t o r t s the s h e e t s , and
t h e r e a r e a l s o indications ( r e f . 14-9) that it l o w e r s the s a l t - s p r a y r e s i s t -
a n c e of the bonds m a d e with c e r t a i n a d h e s i v e s .
H e a t - t r e a t e d 17 -7PH s t a i n l e s s s t e e l usually h a s s c a l e on the s u r f a c e .

P r o l o n g e d t r e a t m e n t s with one of the above etching t r e a t m e n t s m a y b e
n e c e s s a r y to r e m o v e this s c a l e .
14-1 1

- ~~ -.____
MIL-HDBK-23A CHG N O T I C E 3 9999970 0348340 736 m
14.2.1.7 Titanium S u r f a c e P r e p a r a t i o n
S a t i s f a c t o r y adhesive bonding t o t i t a n i u m s u r f a c e s can s o m e t i m e s be

accomplished by s i m p l e a b r a s i v e b l a s t i n g o r a c i d etching. This s i m p l e
cleaning t r e a t m e n t is not sufficient when bonds a r e to b e exposed t o e l e v a t e d
t e m p e r a t u r e s o r high humidity. S u r f a c e p r e p a r a t i o n f o r t h e s e environments
m u s t include a c h e m i c a l o r anodic s e a l .
L i k e aluminum, t i t a n i u m is a v e r y r e a c t i v e m e t a l which depends upon

t h e f o r m a t i o n of a c h e m i c a l l y i n e r t n a t u r a l oxide f i l m f o r its v e r y high c o r -
r o s i o n r e s i s t a n c e . Titanium differs f r o m aluminum and many o t h e r m e t a l s
i n that the oxidation p r o c e s s depends on t h e r e a c t i o n between oxygen and
t i t a n i u m o c c u r r i n g at the m e t a l - m e t a l oxide interface; i. e . , the oxygen
r a t h e r than the m e t a l diffuses through the oxide s c a l e . T h i s diffusion p r o c e s s
r e s u l t s in the f o r m a t i o n of a non-adherent i n n e r l a y e r of s c a l e , and i s g r e a t l y
a c c e l e r a t e d when s u r f a c e s which a r e not completely s e a l e d f r o m oxygen con-
t a c t a r e subjected to e l e v a t e d t e m p e r a t u r e s o r high humidity.
G e n e r a l s u r f a c e cleaning i s u s u a l l y accomplished by wiping with a non-

chlorinated solvent, followed by i m m e r s i o n in a hot alkaline c l e a n e r of the
type n o r m a l l y u s e d f o r s t e e l . (Vapor d e g r e a s i n g is not r e c o m m e n d e d , due
t o the danger of t r i c h l o r o e t h y l e n e r e s i d u e s on the s u r f a c e causing s t r e s s
c o r r o s i o n during any subsequent e x p o s u r e a t t e m p e r a t u r e s above 600" F.)
A b r a s i v e blasting c a n be u s e d to r e m o v e the non-adherent n a t u r a l oxide

l a y e r , and t o i n c r e a s e t h e a r e a of the s u r f a c e in o r d e r to i m p r o v e the
m e c h a n i c a l bonding of the adhesive. A b r a s i v e b l a s t cleaning may be a c c o m -
plished e i t h e r wet o r d r y , g e n e r a l l y using 180- to 3 2 5 - m e s h aluminum oxide
o r g a r n e t t o avoid e x c e s s i v e roughening o r contamination of the t i t a n i u m .
In o r d e r to avoid e x c e s s i v e build-up of the n o n - a d h e r e n t n a t u r a l oxide l a y e r ,
t i t a n i u m p a r t s m u s t be adhesive bonded, p r i m e d , o r c h e m i c a l l y s e a l e d within
2 h o u r s a f t e r blasting.
Acid etching is u s e d t o r e m o v e h e a t treat s c a l e , t h e n a t u r a l oxide l a y e r

and the top l a y e r of oxygen-contaminated titanium (alpha c a s e ) . This p r o -
d u c e s a v e r y s m o o t h s u r f a c e which is c h e m i c a l l y c l e a n and v e r y r e a c t i v e .
S u r f a c e s must be bonded, p r i m e d , o r c h e m i c a l l y s e a l e d within 2 h o u r s after
etching. Etching is g e n e r a l l y a c c o m p l i s h e d by i m m e r s i n g f o r 10 minutes in
t h e following solution:
2 - 8 ounces p e r gallon of hydrofluoric a c i d (HF)

30-65 ounces p e r gallon of n i t r i c a c i d ("O3)
1O:l minimum r a t i o HNO3:HF
O. 0025-0.0050 e t c h r a t e (inches p e r s i d e p e r h o u r )
120' - 135" F t e m p e r a t u r e .
-
~ _ _
14-12
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_____
= 9999970 OL48141 =
-
MIL-HBBK-23A CHG N O T I C E 3 672
Titanium s u r f a c e s m a y b e s e a l e d e i t h e r chemically o r anodically. The

s e a l coating r e a c t i o n is e s s e n t i a l l y a controlled c o r r o s i o n reaction in which
a c o r r o s i o n - p r e v e n t i n g , reaction-product film is f o r m e d . The reaction
product, itself intimately a d h e r e n t to the m e t a l , s e r v e s to s e a l titanium
f r o m contact with oxygen and m a k e s a good b a s e f o r bonding. The chemical
sealing solutions a r e acidic and contain an attacking agent ( P - ) , a f i l m -
forming agent ( C r O
- - o r P O 4 - - - ) , and s o m e t i m e s a moderating agent
4
(NO -). The anodic sealing solutions contain a chelating agent o r an active
3
acid to attack the titanium, and a n acidic o r alkaline e l e c t r o l y t e to i n c r e a s e
conductivity. Anodic sealing s e r v e s to electrolytically oxidize the titanium
a t the m e t a l - m e t a l oxide i n t e r f a c e with no significant p a r t growth. Anodic
coatings a r e not good b a r r i e r s against f u r t h e r oxidation, and g e n e r a l l y
r e q u i r e sealing with a s i l a n e p r i m e r p r i o r to bonding.
I
A c h e m i c a l s e a l which is f a i r l y effective i n preventing l o s s of s t r e n g t h

when bonds a r e exposed t o elevated t e m p e r a t u r e (up to 6 0 0 " F with the
p r o p e r adhesive) o r high humidity, i s a 15 to 30 minute t r e a t m e n t with a
solution containing 50 to 70 p e r c e n t by volume of P a s a - J e l l 107C in w a t e r .
This is a solution containing n i t r i c , c h r o m i c , and fluosilicic a c i d s . The
solution e t c h r a t e i s n o r m a l l y maintained a t O . 02 t o O. 04 mil p e r side p e r
hour by additions of the m a k e up liquid o r hydrofluoric acid.
A c h e m i c a l s e a l which i s somewhat l e s s effective in preventing t h e r m a l

o r humid degradation of bonds is a 1 to 3 minute t r e a t m e n t in the following
solution:
6 . 3 - 6 . 7 ounces p e r gallon of sodium phosphate dodecahydrate

2 . 5 - 4. O ounces p e r gallon of potassium fluoride dihydrate
2 . O - 2 . 8 ounces p e r gallon of hydrofluoric acid ( a s H F )
Balance w a t e r
After s e a l i n g , titanium s u r f a c e s should b e thoroughly r i n s e d in w a t e r

containing l e s s than 6 p a r t s p e r million of c h l o r i d e s , and then a i r d r i e d .
P r o p e r l y applied s e a l coatings will prevent reoxidation of titanium s u r f a c e s
during s t o r a g e f o r 16 h o u r s o r m o r e . Nevertheless,bonding should be
accomplished as soon as possible a f t e r sealing.
- 14- 13
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

14.2.2 Method of Armlving Adhesives
A f t e r the c o r e s and facings have been p r o p e r l y p r e p a r e d f o r bonding,

the a d h e s i v e s a r e applied. The method of application will depend on the f o r m
of t h e adhesive, and the adhesive m a n u f a c t u r e r ' s recommendations should be
c l o s e l y followed. G e n e r a l r e q u i r e m e n t s with r e s p e c t t o the applying of the
a d h e s i v e a r e given i n M i l i t a r y Specification MIL-A-9067 ( r e f . 14-10). The
t h i n n e r solutions a r e f o r m u l a t e d f o r u s e as s p r a y a b l e p r i m e r s o r f o r applica-
tion i n multiple coats by spraying. The m o r e viscous solutions a r e designed
f o r application by b r u s h , hand r o l l e r , s c r a p e r , r o l l glue s p r e a d e r , and by
d i r e c t e x t r u s i o n of the adhesive. The powdered and s o l i d epoxy-resin adhe-
s i v e s a r e applied by sprinkling o r rubbing on o v e r heated ( 2 0 0 " F ) metal
s u r f a c e s . The film o r tape adhesives a r e s i m p l y laid in p l a c e , and i f
n e c e s s a r y c a n be tacked i n position a t s e v e r a l places by m o m e n t a r i l y touch-
ing a hot i r o n to t h e film o r tape, o r by moistening with solvent followed by
air o r f o r c e d a i r drying.
14.2.2. 1 Application by Spraying
Spraying is g e n e r a l l y u s e d i n applying thin solvent solutions of adhesive

t o a uniform s p r e a d , p a r t i c u l a r l y o v e r l a r g e a s s e m b l i e s that m a y involve
thin facings o r complicated c u r v e d s h a p e s . This method is usually limited
t o applying adhesives on facings o r on solid c o r e s , but s e v e r a l f a b r i c a t o r s
have a l s o u s e d s p r a y i n g methods to apply adhesives to honeycomb c o r e s .
However, t h e s p r a y i n g techniques with t h e v a r i o u s adhesives w i l l v a r y
slightly depending on the c h e m i c a l types of r e s i n s and solvents u s e d ; the
thinning of the adhesive and s p r a y i n g should b e done a s r e c o m m e n d e d by
the adhesive m a n u f a c t u r e r .
P r e s s u r e - c u p s p r a y equipment is frequently u s e d in applying adhesives

in production work. It is then possible to keep the adhesive in l a r g e r quanti-
ties in a s e p a r a t e p r e s s u r i z e d tank and feed the s p r a y gun a t o m i z e r through
flexible h o s e s connected to the tank. M o r e viscous types of adhesives can
a l s o b e m o r e s u c c e s s f u l l y s p r a y e d by using p r e s s u r e - c u p equipment.
Many of the adhesive p r i m e r s u s e d i n combination with film and tape

a d h e s i v e s a r e also applied by s p r a y i n g . T h e s e adhesive p r i m e r s a r e usually
applied in a single thin coat to m a i n t a i n the s u r f a c e c l e a n l i n e s s of the m e t a l
s h e e t s , and t o provide good "wetting" between t h e adhesive on the film and
t a p e s and the s u r f a c e s of the adherend.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
When possible, s u r f a c e s should b e t u r n e d between c o a t s s o that s u c c e s s i v e

c o a t s c a n be applied at right angles t o e a c h o t h e r t o m i n i m i z e i r r e g u l a r
adhe s i v e films.
-14-14 -
----.

T h e application of adhesive by s p r a y i n g g e n e r a l l y r e s u l t s in a uniform
film w i t h a m i n i m u m of s u c h s u r f a c e defects as pin h o l e s , b l i s t e r s , and
runs. With c e r t a i n a d h e s i v e s that have good flow c h a r a c t e r i s t i c s while c u r -
ing u n d e r p r e s s u r e , s o m e s u r f a c e defects can b e t o l e r a t e d . The defects
e n c o u n t e r e d i n s p r a y i n g a r e s o m e t i m e s c h a r a c t e r i s t i c of the adhesive f o r m -
ulation being s p r a y e d , but s o m e defects m a y have additional c a u s e s , a s
follows:
1 . E x c e s s i v e cobwebbing of the adhesive s p r a y m a y b e f r o m using a

high a i r - t o - a d h e s i v e r a t i o f o r t h e gun, using low-boiling point s o l v e n t s , o r
holding t h e s p r a y gun too far f r o m the work. Using the gun at e x c e s s i v e
d i s t a n c e s f r o m the w o r k r e s u l t s in the solvent volatilizing too much before
t h e s p r a y s t r i k e s the s u r f a c e .
2. O r a n g e - p e e l effect and wrinkling of the s u r f a c e film may be due to

high air p r e s s u r e s , e x c e s s i v e adhesive application, holding the gun too
Close to the w o r k , incomplete atomizing of the a d h e s i v e , o r to the u s e of
adhesive solutions that do not contain enough high-boiling solvents to allow
sufficient flow for the s u r f a c e t o smooth out before drying.
3 . * Pinholes and bubbles in the adhesive f i l m m a y be due to the u s e of

too heavy a n application of a d h e s i v e , the u s e of adhesive f o r m u l a t i o n s that
have been thinned e x c e s s i v e l y with low-boiling solvents, o r to the applica-
tion of s u c c e s s i v e adhesive coats o v e r adhesive c o a t s that have not d r i e d
suffi c i ent ly .
4. Blushing (a dull, cloudy effect on t h e s p r a y e d s u r f a c e ) of the adhesive
f i l m m a y b e due t o the condensation of m o i s t u r e on the s u r f a c e during s p r a y -
ing o r to the inclusion of m o i s t u r e i n t h e adhesive. Condensed m o i s t u r e i s
often due t o t h e cooling of the a t m o s p h e r e above the w o r k by the r a p i d evap-
o r a t i o n of the adhesive s o l v e n t s . F a c t o r s that contribute to condensation
a r e high t e m p e r a t u r e s and r e l a t i v e humidities in the s p r a y r o o m , low t e m -
pe.ratures of the m a t e r i a l s being coated, adhesive solvents with e x c e s s i v e l y
low boiling points, and high r a t e of a i r flow1 a c r o s s the drying film. A num-
b e r of the r e g u l a r l y f o r m u l a t e d a d h e s i v e s f o r s p r a y i n g can be u s e d in
a t m o s p h e r i c conditions of 55" t o 7 5 " F , provided the relative humidity i s
55 p e r c e n t o r l e s s . Spraying c a n be done a t t e m p e r a t u r e s a s high as 100" F,
but then the r e l a t i v e humidity should not exceed 30 p e r c e n t . Some a d h e s i v e s ,
b e c a u s e of the composition of the r e s i n o r solvents u s e d , a r e l e s s s e n s i t i v e
to a t m o s p h e r i c m o i s t u r e conditions, and can b e s p r a y e d a t h i g h e r humidities.
5. Running of the adhesive f i l m m a y b e c a u s e d by overthinning, using

high-boiling solvents that do not volatilize rapidly enough, o r applying too
much a d h e s i v e .
14-15
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-~
MIL-HDBK-23A CHG N O T I C E 3 = 9999970 0148144 381 W

6. Lifting o r b l i s t e r i n g of the adhesive f i l m is s a i d to be c a u s e d when a
heavy c o a t of adhesive is applied o v e r an adhesive p r i m e coat that has not
been allowed to a i r - d r y long enough.
7. I r r e g u l a r p a r t i c l e s in the adhesive film m a y b e c a u s e d by i m p r o p e r

mixing and thinning of the adhesive, over-aged adhesive, blocked air p a s s a g e s
i n the gun, m o i s t u r e and i m p u r i t i e s entering the gun f r o m the air supply,-
d r i e d adhesive p a r t i c l e s being deposited by using the gun too f a r f r o m the
w o r k , too high a n a i r - t o - a d h e s i v e r a t i o f o r the gun, o r by the u s e of a low-
boiling solvent .
14.2.2.2 Application by Other Methods
O r d i n a r y brushing of the adhesive can be u s e d if the a r e a s a r e s m a l l

and difficult t o m a s k , i f t h e adhesive is viscous and thinning is not r e c o m -
mended, o r i f s p r a y i n g equipment i s not available. Hand r o l l e r s and con-
ventional r o l l glue s p r e a d e r s a r e frequently u s e d when applying liquid a d h e -
s i v e s to the c o r e s of sandwich construction. One company has a l s o devel-
oped a n e x t r u s i o n method by which a w e t film of the adhesive can b e
extruded d i r e c t l y upon the c o r e o r facings of the sandwich panel. This
method is s a i d to produce good "filleting" action to honeycomb-type c o r e s .
The adhesive f o r m u l a t e d f o r application by t h e s e methods is g e n e r a l l y of
higher viscosity than those intended f o r s p r a y application.
Film and tape adhesives a r e s i m p l y laid in place, s o m e t i m e s a f t e r f i r s t

priming of the c o r e and facings with a liquid p r i m e r . While not g e n e r a l l y
recommended, h e a t "tacking" ( t e m p e r a t u r e should be below curing t e m p e r -
a t u r e f o r adhesive) o r solvent "tacking" m a y be u s e d to i n s u r e that the adhe-
s i v e film w i l l s t a y in place during any operations p r i o r to bonding. After
solvent "tacking" sufficient air o r f o r c e d - a i r drying should b e u s e d t o
i n s u r e solvent r e l e a s e . If t h e s e solvents a r e r e t a i n e d within the a s s e m b l y ,
poor core-to-facing bonds o r b l i s t e r i n g m a y o c c u r when the a s s e m b l y is
removed f r o m the bonding p r e s s e s .
14-16
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

.__ ~~ -
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0148145 218
14.2.2.3 Amounts of Adhesive Applied
The amount of adhesive applied is dependent upon a n u m b e r of f a c t o r s ,

s u c h a s the type of adhesive u s e d , the type and f i t of the s u r f a c e s being
bonded, and the d e g r e e of adhesive flow during the formation of the joints.
The adhesive m a n u f a c t u r e r s g e n e r a l l y r e c o m m e n d t h a t , when bonding m e t a l
to m e t a l with the liquid a d h e s i v e s , sufficient adhesive be applied to r e s u l t in
a final bond-line thickness of 0.002 to 0 , 0 0 5 inch. Adhesives supplied in
film f o r m range in thickness f r o m O . 003 t o O. 030 inch (O. 015 to O . 180 pounds
p e r s q u a r e foot) with the t h i c k e r supported films o r combinations of the
thinner f i l m s generally being used when bonding panels of honeycomb c o r e s .
When liquid adhesives a r e used f o r bonding t o honeycomb c o r e s , it i s gen-
e r a l l y d e s i r a b l e to apply the adhesive to the c o r e s o that the adhesive will
c o v e r the c o r e s u r f a c e , extend down into c o r e , and s u r r o u n d the ends of
the c e l l walls f o r 1 / 3 2 to 1 / 1 6 inch. R o l l e r coating, s p r a y i n g , o r extrusion
p r o c e d u r e s a s outlined under section 1 4 . 2 . 2 . 2 a r e s a t i s f a c t o r y methods for
applying t h e s e priming adhesives to the honeycomb c o r e s . Most manufac-
t u r e r s of sandwich construction t r y to control the total amount of adhesive
applied in bonding the sandwich panels to a d r y weight of O. 15 to O . 2 5 pounds
p e r s q u a r e foot of sandwichpanel; this control gives economy and low panel
w e i g h t s , c s c c p t when the h e a v i e s t of the f i l m adhesives a r e being used.
14.2.2.4 Assembly P e r i o d in Bonding
The a s s e m b l y period, which i s the t i m e between spreading and applica-

tion of the p r e s s u r e and curing t e m p e r a t u r e , m u s t be controlled to allow
volatile solvents to e s c a p e f r o m the film and to obtain s o m e initial setting
of the adhesive. This setting m u s t not be s o advanced that t h e r e will be
inadequate flow and wetting of the e n t i r e adherend s u r f a c e s during the final
p r e s s i n g . This a s s e m b l y period m a y be e i t h e r in open a s s e m b l y o r with
the s u r f a c e s placed together in position f o r bonding. Open a s s e m b l y p e r -
iods a r e g e n e r a l l y u s e d when bonding nonporous m e t a l - t o - m e t a l o r sandwich
panels,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
14-17

____-_ ___- --__-
MIL-HDBK-23A C H G N O T I C E 3 W 7 0 014146 154 =

The adhesive m a n u f a c t u r e r ' s recommendations regarding the a s s e m b l y
p e r i o d s t o b e u s e d with e a c h formulation of adhesive should be c l o s e l y fol-
lowed. With the liquid e p o x y - r e s i n adhesives and the o t h e r adhesives f o r m -
ulated f o r r a p i d curing at o r n e a r n o r m a l shop t e m p e r a t u r e s , m a x i m u m
a s s e m b l y period should be s h o r t ; usually less than 30 m i n u t e s , depending
on the adhesive formulation and r o o m t e m p e r a t u r e s , s o that the a s s e m b l y
can be m a d e and p r e s s u r e applied before t h e r e i s p a r t i a l setting of the adhe-
s i v e . With the e l e v a t e d - t e m p e r a t u r e -setting adhesives that contain volatile
s o l v e n t s , it is n e c e s s a r y t o air d r y the adhesive, after it is s p r e a d , to
r e m o v e e x c e s s solvents t h a t might o t h e r w i s e c a u s e e x c e s s i v e flow o r b l i s -
t e r i n g of the final bond. A s s e m b l y periods of 8 to 24 h o u r s a f t e r applying
t h e adhesive a r e frequently u s e d with the elevated-temperature-settting
metal-bonding a d h e s i v e s . With s o m e of t h e s e a d h e s i v e s , a s s e m b l y periods
of s e v e r a l months have been s u c c e s s f u l l y u s e d , when the adhesive s u r f a c e
is p r o t e c t e d f r o m contamination.
When it i s m o r e convenient to u s e s h o r t a s s e m b l y periods (1 to 8 h o u r s ) ,

p r e c u r i n g of the adhesive film (at a t e m p e r a t u r e below the curing t e m p e r a -
t u r e of the adhesive and without p r e s s u r e ) is often u s e d to adequately remove
the solvents and to provide the d e s i r e d d e g r e e of flow during the actual p r e -
curing operation. With s o m e a d h e s i v e s , p r e c u r i n g is r e q u i r e d even follow -
ing open a s s e m b l y periods of 8 to 24 h o u r s b e c a u s e of the slow r a t e of evap-
o r a t i o n of solvents f r o m the adhesive film. The amount of p r e c u r i n g should --
be carefully controlled, following the adhesive m a n u f a c t u r e r ' s r e c o m m e n d a -
t i o n s , as e x c e s s i v e p r e c u r i n g often r e s u l t s in weak bonds beca.use of inade-
quate flow of the adhesive during final c u r e . In addition to reducing flow and
b l i s t e r i n g tendencies during c u r e , adequate p r e c u r i n g will, with c e r t a i n
a d h e s i v e s , i m p r o v e t h e bond s t r e n g t h s a t elevated t e m p e r a t u r e s . P r e c u r i n g
conditions v a r y f r o m drying in a f o r c d - a i r oven f o r 3 0 minutes to 2 h o u r s
at t e m p e r a t u r e s f r o m 180" to 230" F , to p r e c u r i n g on the platens of a
p r e s s without p r e s s u r e o r at low p r e s s u r e s ( 3 pounds p e r s q u a r e inch) f o r
5 to 15 minutes until the n o r m a l curing t e m p e r a t u r e f r o m 3 0 0 " to 335" F
is r e a c h e d , r e l e a s i n g p r e s s u r e m o m e n t a r i l y , and then applying full curing
pressure,
If t h e adhesive film b l i s t e r s when p r e c u r e d , the application of the

adhesives h a s probably b e e n too heavy, the a i r - d r y i n g period p r i o r t o p r e -
curing h a s been too s h o r t , o r the p r e c u r i n g t e m p e r a t u r e being u s e d is too
high.
14-18
.-
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- _ _ _ - ~ __-___ ~- __ - ~
NIL-HDBK-23A CHG N O T I C E 3 9999970 OL4L47 0 9 0
1 4 . 2 . 2 . 5 Curing T i m e and T e m p e r a t u r e
Cons ide rations
T h e f i n a l c h e m i c a l r e a c t i o n of curing of the components of the adhesive

into a s t r o n g film r e q u i r e s the application of elevated t e m p e r a t u r e s . The
s e l e c t i o n of the curing t i m e and t e m p e r a t u r e , and even the r a t e of heating
r e q u i r e d , a r e dependent on the adhesive formulation, the type of joint, and
the s e r v i c e condition expected f o r the bond. The adhesive m a n u f a c t u r e r ' s
recommendations should be carefully c o n s i d e r e d in establishing the curing
conditions to be u s e d i n fabrication of the bonded a s s e m b l i e s . Details on
the type of equipment u s e d in obtaining the p r o p e r curing t e m p e r a t u r e s in
the bond a s s e m b l i e s a r e d e s c r i b e d in section 14.4. 1. 1.4.
The e l e v a t e d - t e m p e r a t u r e - s e t t i n g adhesives a r e usually c u r e d by m a i n -

taining bond-line t e m p e r a t u r e a t 325" to 350" F for 30 minutes to 2 h o u r s .
S o m e of t h e s e h i g h - t e m p e r a t u r e - s e t t i n g adhesives show practically no
evidence of c u r e a t t e m p e r a t u r e s lower than 300" F ; o t h e r s a r e s a i d to c u r e
partially a t t e m p e r a t u r e s a s low a s 250" F if the curing period i s greatly
i n c r e a s e d . C e r t a i n formulations of the epoxy-resin adhesives can be c u r e d
at 180" to 2 0 0 " F and m o d e r a t e l y s t r o n g bonds a r e obtainable with s o m e
s p e c i a l formulations of this type of adhesive w h e n c u r e d at n o r m a l shop t e m -
peratures.
P o s t - c u r i n g of panels bonded with h e a t - r e s i s t a n t adhesives is being done

to a limited extent. T h i s postciiring is done a t elevated t e m p e r a t u r e s , after
the panels a r e r e m o v e d f r o m the p r e s s , to obtain higher h e a t - r e s i s t a n c e
p r o p e r t i e s of the adhesive bond.
14.2.2.6 Bonding P r e s s u r e
Adequate p r e s s u r e m u s t be maintained during the final c u r e o the adhe-

s i v e bond to ( i ) obtain uniformly thin adhesive bond l i n e s , (2) o v e r c o m e
v i s c o s i t y of adhesive film a t the curing t e m p e r a t u r e , ( 3 ) o v e r c o m e i n t e r n a l
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
p r e s s u r e e x e r t e d by r e l e a s e of adhesive s o l v e n t s , and (4) o v e r c o m e the s u r -

f a c e imperfections (within l i m i t s ) between mating s u r f a c e s o r the lack of
f l a t n e s s in the skin m a t e r i a l s . T h e p r e s s u r e r e q u i r e d f o r bonding i s not a
constant f o r any one adhesive, nor i s i t a constant for a l l a s s e m b l i e s .
P r e s s u r e i s r a t h e r a function of a s i z e of the bonded p a r t s , the perfection
of the mating s u r f a c e s , the v i s c o s i t y of the adhesive a t curing t e m p e r a t u r e ,
and i n t e r n a l p r e s s u r e due to solvent v a p o r s .
14-19
i
--- - -

-- _ _
flIL-HBBK-23A CHG N O T I C E 3 = 9999970 OI14L48 " 2 7
In bonding facings t o c o r e m a t e r i a l s , bonding p r e s s u r e s u p to the m a x i m u m
p r e s s u r e t h a t t h e c o r e m a t e r i a l can withstand at t h e bonding t e m p e r a t u r e can
b e u s e d . P r e s s u r e s of approximately 14 pounds p e r s q u a r e inch, n o r m a l
vacuum p r e s s u r e , a r e frequently u s e d in bonding t o honeycomb c o r e s . A
rough f a c t o r of 10 times t h e c o r e density in pounds p e r cubic foot m a y b e u s e d
as t h e m a x i m u m c u r i n g p r e s s u r e in pounds p e r s q u a r e inch f o r aluminum alloy
c o r e s . P r e s s u r e s u p to 200 pounds p e r s q u a r e inch a r e r e c o m m e n d e d f o r
making m e t a l - t o - m e t a l bonds. In bonding sandwich panels containing m e t a l
i n s e r t s and edgings, i t i s frequently n e c e s s a r y t o design s p e c i a l f i x t u r e s s o
t h a t t h e higher p r e s s u r e s c a n b e applied i n t h e a r e a s of t h e m e t a l - t o - m e t a l
bonding. Bonding of sandwich panels by p r e s s i n g t o s t o p s c a n a l s o b e done i f
c a r e is taken to s e e t h a t t h e r e is no crushing of t h e c o r e . T h e m a x i m u m
p r e s s u r e s f o r t h e v a r i o u s c o r e m a t e r i a l s and d e t a i l s on methods of applying
bonding p r e s s u r e s on sandwich p a r t s a r e d i s c u s s e d in section 1 4 . 4 . 1 .
14.3 BRAZED O R WELDED SANDWICH CONSTRUCTION
Metallic sandwich construction f o r u s e a t elevated t e m p e r a t u r e s can be

f2 ~ r i c a t e dby b r a z i n g o r welding facings t o a c o r e ( r e f . 1 4 - 1 , 14-7). Con-
s t r u c t i o n s being m a d e today c o m p r i s e facings and c o r e of h e a t - r e s i s t a n t
s t a i n l e s s s t e e l , usually the 17-7PH, PH15-7Mo, o r AM350 a l l o y s ; nickel-
b a s e and titanium a l l o y s , and alloys of r e f r a c t o r y m e t a l s s u c h as molybdenum
and columbium. C o r e p i e c e s a r e b e s t a s s e m b l e d by tack welding.
All sandwich components, c o r e , f a c i n g s , and b r a z e a r e cleaned by d e -

g r e a s i n g , followed by etching i f n e c e s s a r y .
B r a z i n g of sandwich m u s t be done in a reducing a t m o s p h e r e , i n e r t a t m o s -

p h e r e , o r in a v a c u u m ; o t h e r w i s e , thin c o r e foils and thin facings w i l l c o r r o d e
s e v e r e l y . S u c c e s s f u l sandwich h a s been m a d e by using a d r y hydrogen a t m o s -
p h e r e (dew point at -40" F ) o r a t m o s p h e r e s of helium o r argon. C a r e m u s t
be taken to p u r g e p r o p e r l y the c h a m b e r o r envelope containing the sandwich
b e f o r e i t is heated to b r a z i n g t e m p e r a t u r e s . Cooling m u s t b e done in a con-
t r o l l e d a t m o s p h e r e o r vacuum s o as to p r e v e n t c o r r o s i o n . A p r e s s u r e dif-
f e r e n t i a l is maintained between t h e brazing r e t o r t and the envelope containing
t h e sandwich, s o t h a t t h e sandwich components will be held in c o n t a c t . B r a z -
ing t e m p e r a t u r e s a r e dependent ripon the b r a z e alloy and, with p r o p e r selection
of b r a z e alloy, compatible b r a z i n g and h e a t - t r e a t i n g c y c l e s c a n be u t i l i z e d .
Heat t r e a t i n g m u s t a l s o b e done i n an a t m o s p h e r e o r v a c u u m .
14-20
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

7 -- . ______.
MIL-HDBK-23A CHG N O T I C E 3 = 9999970 Olt48149 963

S e v e r a l brazing alloys have been u s e d to bond facings t o c o r e s . E a r l y
a t t e m p t s w e r e on copper that w a s plated on the c o r e , o r s h e e t s of nickel
b r a z e composed of 8 2 . 5 p e r c e n t n i c k e l , 4. 5 p e r c e n t s i l i c o n , 2 . 9 p e r c e n t
b o r o n , 7 . ( ' p e r c e n t c h r o m i u m , and 3 . O p e r c e n t i r o n . S i l v e r a l l o y s . such
as 85 p e r c e n t silver, and 15 p e r c e n t m a n g a n e s e , o r 9 2 . 5 p e r c e n t s i l v e r
7 p e r c e n t c o p p e r . and p . 5 p e r c e n t l i t h i u m , have been u s e d s u c c e s s f u l l y .
F a c i n g s can a l s o be welded to c o r e s . C o r r u g a t e d c o r e s , waffle c o r e s , o r

flanged honeycomb c o r e s have been spot-welded to f a c i n g s . S o m e s u c c e s s
h a s a l s o been had with a projection weld between a honeycomb c o r e and
f a c i n g s . T h i s weld can be obtained by placing a fine w i r e s c r e e n between
t h e c o r e and facing o r by using facings on which a g r i d i s etched.
Inspection of b r a z e d sandwicn c a n b e aided by u l t r a s o n i c inspection and

X - r a y photographs that show whether b r a z i n g is o r is not uniform between
facings and c o r e , l o c a l a r e a s of c r u s h e d c o r e , open c o r e j o i n t s , and other
d e f e c t s that m a y b e p r e s e n t .
1 4 . 4 SANDWICH PRODUCTION TECHNIQUES
Sandwich constructions c u r r e n t l y in u s e in a i r f r a m e s , o r in the e x p e r i -

m e n t a l s t a g e s of f a b r i c a t i o n , a r e of many combinations of c o r e s and facings.
T h e combination of facing m a t e r i a l s and c o r e s to m a k e sandwich c o n s t r u c -

tions f o r s p e c i f i c applications i s a l m o s t infinite. F i g u r e 1 3 - 13 i l l u s t r a t e s
two of the combinations that a r e finding limited u s e f o r highly specialized
applications. T h e socalled m u l t i - c o r e sandwich is composed of l a y e r s of
c o r e m a t e r i a l in the f o r m of c u r e d f o a m , interleaved by single l a y e r s of
g l a s s f a b r i c and r e s i n . Constructions of this type a r e s o m e t i m e s u s e d f o r
highly specialized d i e l e c t r i c a p p l i c a t i o n s . T h e second construction i l l u s t r a t e d
in f i g u r e 13-13 i s s o m e t i m e s r e f e r r e d to as a "fluted c o r e sandwich. I ' I t i s
m a d e by the l o s t wax p r o c e s s . and o f f e r s opportunity of t r a n s m i t t i n g a fluid
in e a c h of the t i e r s of c o r e f o r purposes of heating o r cooling.
Sandwich p a r t s in a i r f r a m e s ' a r e of any configuration f r o m flat to s e v e r e

compound c u r v a t u r e ; consequently, a f a b r i c a t i o n technique m u s t be chosen
that can be adapted m o s t readily to the s p e c i f i c c o r e - f a c i n g combination and
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
configuration.
F a b r i c a t i o n techniques m a y be divided into c l a s s e s according to c u r v a t u r e

of product, type of facing o r c o r e , equipment r e q u i r e d , method of applying
p r e s s u r e , o r according t o s o m e o t h e r c h a r a c t e r i s t i c . F o r the purposes of
this d i s c u s s i o n , techniques a r e c l a s s e d principally according to t h e method
u s e d t o apply p r e s s u r e .
14-2 1
1
:

______-
.
c
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 OI148L50 68.5 m
In the fabrication of sandwich panels and the bonding of attachment
fittings, it is s o m e t i m e s n e c e s s a r y to subject s o m e of the adhesive bonds to
s e v e r a l curing cycles. T h e s e r e p e a t e d c u r e s , within the n o r m a l curing
t e m p e r a t u r e range f o r the a d h e s i v e s , do not d e t e r i o r a t e the quality of bonds
m a d e with the s t r u c t u r a l type of metal-bonding adhesives. T e s t s ( r e f . 14-8)
m a d e at 350" F on adhesive bonds g e n e r a l l y showed b e t t e r s t r e n g t h s a f t e r
being aged f o r 192 and 1 , 0 0 0 h o u r s at 350" F than when t e s t e d a f t e r the
o r i g i n a l curing cycle.
14.4.1
- Means of Applying P r e s s u r e
14.4.1.1 Fluid P r e s s u r e
T h e molding of sandwich p a r t s by m e a n s of fluid p r e s s u r e applied

through flexible bags o r blankets of i m p e r m e a b l e m a t e r i a l h a s found i n c r e a s -
ing application i n making sandwich p a r t s of v a r i o u s d e g r e e s of c u r v a t u r e in
the last five y e a r s . Typical p a r t s include a l l combinations of single and
compound c u r v a t u r e , c y l i n d e r s , paraboloids, portions of a s p h e r e - - i n s h o r t ,
any piece f o r which a mold c a n b e m a d e and l a t e r s e p a r a t e d f r o m the fin-
i s h e d product.
-
T h e fundamental p r o c e d u r e of molding with fluid p r e s s u r e is t h e s a m e
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f o r all p r o c e s s e s on c o m m o n u s e . In p r i n c i p l e , the technque c o n s i s t s of

attaching t e m p o r a r y s u p e r - i m p o s e d l a y e r s of facings and c o r e i n a mold of
the d e s i r e d s h a p e , and molding t h e s e into a unit s t r u c t u r e by the application
of h e a t and fluid p r e s s u r e through a bag o r blanket. The fluid m a y b e a i r ,
s t e a m , s t e a m - a i r m i x t u r e , o r an i n e r t g a s . P r o c e s s e s a r e relatively
s i m p l e and provide a m e a n s by which sandwiches c a n b e produced of single
o r compound c u r v a t u r e , and of constant o r varying thickness in any a r r a n g e -
m e n t of facings and c o r e . F l a t sandwich p a r t s can a l s o be m a d e by fluid
p r e s s u r e molding, but c a n n o r m a l l y be produced m o r e economically by other
m e a n s . T h e f l u i d - p r e s s u r e technique is l a r g e l y l i m i t e d in u s e to the p r o -
duction of p a r t s that c a n be manufactured by no o t h e r p r a c t i c a l m e a n s . In
g e n e r a l , p a r t s t h a t fall in this c a t e g o r y w i l l have one o r m o r e of the follow-
ing c h a r a c t e r i s t i c s : Appreciable compound c u r v a t u r e , v a r i a b l e t h i c k n e s s ,
s i n g l e c u r v a t u r e bends approximating o r exceeding 180", p a r t s too l a r g e to be
m a d e p r a c t i c a b l y by mating d i e s , o r quantity too small t o justify mating dies.
The p r o c e s s e s p e r m i t t h e u s e of t h e r m o s e t t i n g r e s i n s and m e t a l - t o -
m e t a l adhesives with long a s s e m b l y periods. P r e s s u r e s within the range of
10 t o 75 pounds p e r s q u a r e inch a r e common. F i g u r e 14-14 i l l u s t r a t e s d i a -
g r a m m a t i c a l l y t h r e e b a s i c p r o c e s s e s in u s e a t p r e s e n t : A , the vacuum bag
p r o c e s s ; and B and C , techniques capable of employing h i g h e r p r e s s u r e s b y -_
m e a n s of a n autoclave o r a p r e s s u r e c h a m b e r respectively.
_-- _______s__---- --
14-22

MIL-HDBK-23A CHG N O T I C E 3 9999970 0148L51 511 =
14.4. 1.1. 1 Autoclave Molding. - - T h e u s e of autoclave ( s o m e t i m e s called

p r e s s u r e c y l i n d e r s o r t a n k s ) , such as a r e shown d i a g r a m m a t i c a l l y in
f i g u r e 14-14B, h a s g r e a t l y i n c r e a s e d in the p a s t five y e a r s .
Many of t h e s e applications r e q u i r e high t e m p e r a t u r e - c u r i n g m e t a l - t o -

metal a d h e s i v e s , and t h e r e f o r e employ relatively high t e m p e r a t u r e s (-100 O
t o - 5 0 0 " F ) i n the c u r i n g cycle. T h e d i r e c t injection of s t e a m a s a heating

m e d i u m is often i m p r a c t i c a l a t t h e s e t e m p e r a t u r e s , and i m p o s s i b l e if the
p r e s s u r e r e q u i r e d is relatively low (25 to 50 pounds p e r s q u a r e inch). A i r ,
heated by m e a n s of e l e c t r i c r e s i s t a n c e h e a t e r s o r Dowtherm u n i t s , is t h e r e -
f o r e often u s e d as the p r e s s u r e - and h e a t - t r a n s f e r fluid. Many p r o b l e m s
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
a r i s e with the u s e of a g a s s u c h as air as a heating m e d i u m . A l l g a s e s have
low h e a t - t r a n s f e r p r o p e r t i e s , t h e r e f o r e i t is n e c e s s a r y to c r e a t e r a p i d move-
m e n t within the autoclave to i m p r o v e heat t r a n s f e r . The l i b e r a l u s e of t h e r m o -
couples a t typical locations on the p a r t being molded i s r e c o m m e n d e d .
Extreme caution should b e e x e r c i s e d in the o p e r a t i o n of autoclaves s i n c e

v e r y s e r i o u s and s o m e t i m e s unexplained f i r e s have been e s p e r i e n c e d by
s e v e r a l f a b r i c a t o r s . E l e c t r i c heating of any kind m a y be a potential f i r e
h a z a r d due to defective wiring and connections. The combination of c o m -
p r e s s e d hot air and combustible m a t e r i a l s (such as r u b b e r o r plastic bags
o r blankets, oil v a p o r s f r o m the c o m p r e s s o r , and solvent v a p o r s f r o m the
adhesive that m a y b e squeezed through a defective bag o r blanket) i s
exceedingly dangerous and m a y b e a potential explosion h a z a r d . The m a i n -
tenance of a vacuum pump o n the vent f r o m the bonding f i x t u r e (although not
usually done) would l e s s e n the l a t t e r h a z a r d considerably.
In planning s u c h an o p e r a t i o n , all known safety precautions and r e g u l a -

tions should be o b s e r v e d . T h e a i r c o m p r e s s o r should always b e equipped
with an adequate a f t e r - c o o l e r , an oil-vapor f i l t e r , and a device commonly
u s e d in m i n e s to w a r n of explosive m i x t u r e s . T h e lubricating oil in the
c o m p r e s s o r should have a high f l a s h point s o that a m i n i m u m of vapor is
given off. All precautions should be taken to eliminate any s p a r k s in a
cylinder c h a r g e d with hot a i r that contains s o m e o i l v a p o r , a s a dangerous
explosion could r e s u l t .
14-23
Provided by IHS
.
N u m e r o u s f i r e s have been r e p o r t e d in autoclaves when operating under

conditions d e s c r i b e d above. T h e r e f o r e , it is strongly r e c o m m e n d e d that
an i n e r t gas be u s e d in place of air f o r the p r e s s u r e and heating m e d i u m ,
S e v e r a l i n e r t g a s e s a r e p o s s i b i l i t i e s , s u c h as nitrogen, c a r b o n dioxide,
a r g o n , h e l i u m , o r s u p e r h e a t e d s t e a m , However, in all c a s e s the autoclave
should be equipped with a n oxygen d e t e c t o r to w a r n the o p e r a t o r of an oxygen
content that could s u p p o r t combustion or produce a n explosion. Naturally
the u s e of an i n e r t g a s in place of a i r involves additional expense, however,
i n s o m e localities it is r e p o r t e d t h a t nitrogen containing a slight amount of
i m p u r i t i e s c a n be obtained at low cost. This might a l s o b e t r u e of c a r b o n
dioxide. Because the autoclave i s c h a r g e d with a i r at a t m o s p h e r i c p r e s -
s u r e at the t i m e the door i s c l o s e d , it m u s t be purged before e a c h p r e s s u r e
cycle to reduce t h e oxygen content to a s a f e level. Although m o s t of the
i n e r t g a s r e q u i r e d to c h a r g e the autoclave can be r e u s e d , provided adequate
equipment i s installed, t h e r e is s o m e l o s s of i n e r t gas i n each u s e .
14.4.1.1.2 Molds. - - - T h e forming of any piece by m e a n s of fluid p r e s s u r e

r e q u i r e s s o m e type of mold. T h e s e m o l d s , s o m e t i m e s called f o r m s o r
dies, a r e b r o a d l y c l a s s i f i e d as m a l e o r female. Male molds have the d e s i r e d
s h a p e on the convex s u r f a c e while f e m a l e molds (fig. 14-14, A , B, and C)
have the d e s i r e d shape on t h e concave s u r f a c e . F e m a l e molds a r e u s e d
a l m o s t exclusively f o r all c u r v e d a i r c r a f t sandwich panels, a s smoothness
of the convex s u r f a c e on the finished p a r t i s important. The s u r f a c e of t h e
\
sandwich n e s t to the mold is always s m o o t h e r and h a s a m o r e p r e c i s e con-

t o u r than the s u r f a c e exposed to the bag o r blanket.
M e t a l molds a r e usually m a d e of s h e e t s t e e l , aluminum a l l o y s , o r c a s t

i r o n . Alloys having relatively low melting points a r e a l s o r e p o r t e d to be in
l i m i t e d u s e . Molds of single o r slight compound c u r v a t u r e a r e m a d e of
s h e e t m a t e r i a l 1 / 1 6 to 1 / 4 inch thick. A typical mold of thin s h e e t s t e e l
adequately supported by a s t e e l f r a m e w o r k i s shown in figure 14-15. Two
well-designed b l e e d e r inlets a r e shown on the s u r f a c e , attached t o a c o m -
m o n b l e e d e r connection extending f r o m the end. Molds of s e v e r e compound
c u r v a t u r e , s u c h as f o r r a d o m e s , a r e often c a s t . Thin s h e e t m e t a l molds
have the advantage of rapid h e a t t r a n s f e r , while heavy c a s t m e t a l molds heat
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
m o r e slowly. F o r any kind of externally heated mold, the r a t e of heating i s

affected by t h e heating m e d i u m of which s t e a m i s f a s t e r than a i r o r i n e r t
g a s . M e t a l molds in continuous u s e m a y r e q u i r e cooling before they c a n be
u s e d f o r the next lay-up. This is p a r t i c u l a r l y t r u e of s m a l l molds of con-
s i d e r a b l e thickness. L a r g e molded pieces r e q u i r e a longer t i m e for removal;
consequently, the mold m a y b e sufficiently cooled b e f o r e it is again ready
for use.
14-24

Molds of the type shown in f i g u r e 14-14C, a r e heated internally. They
m a y b e of c a s t i r o n and b e c o r e s f o r s t e a m heating, o r m a y be of a low-melt-
ing alloy poured around a network of copper heating t u b e s . Laminated plastic
molds with i n t e r n a l m e t a l heating tubes a r e a l s o u s e d . Cooling, if n e c e s s a r y ,
m a y be done with cold-water c i r c u l a t i o n . One application of t h i s type of mold
i s f o r producing sandwich s k i n s f o r helicopter b l a d e s .
F e m a l e m e t a l molds have r e c e n t l y been s u c c e s s f u l l y m a d e by m e a n s of an

electrodepositing p r o c e s s on r e u s a b l e c a s t phenolic male f o r m s . Molds of
this type a r e n o r m a l l y about o n e - q u a r t e r inch thick, being deposited f r o m
nickel, a nickel alloy, i r o n , o r c o p p e r , s o m e t i m e s with nickel o r c h r o m e
f a c e s . T h e p r o c e s s i s p a r t i c u l a r l y adaptable to molds of compound c u r v a t u r e .
Molds s e v e r a l f e e t in width and length have been m a d e by this p r o c e s s .
F e m a l e m e t a l molds a r e s o m e t i m e s heated by m e a n s of flexible s t e a m

c o i l s that a r e m e t a l - s p r a y e d in position on the outside s u r f a c e . T h e p r o p e r
spacing a n d configuration of the coils m u s t be d e t e r m i n e d with c a r e to avoid
e x c e s s i v e t e m p c r a t u r e v a r i a t i o n . If the sandwich p a r t being molded i s un-
usually thick ( m o r c than one-half inch) it m a y b e n e c e s s a r y t o provide f o r
supplcmcntal heating on the inside (blanket s i d e ) , T h i s m a y be done with
e l c c t r i c h e a t e r s and fans under a portable canopy in vacuum bag molding, o r
by u s e of a n e l e c t r i c a l l y heated blanket if the molding i s done in an autoclave
using i n e r t g a s as a p r e s s u r e m e d i u m .
One of the m o s t efficient m e a n s of molding with an autoclave and fluid

p r e s s u r e , when many p a r t s of the s a m e s i z e a r e r e q u i r e d , i s the u s e of a
s e l f - h e a t e d mold and unheated a i r ( f o r p r e s s u r e ) . The mold in this c a s e is
usually of m e t a l o r g l a s s - f i b e r - r e i n f o r c e d p l a s t i c , with the h e a t being supplied
by m e a n s of e l e c t r i c r e s i s t a n c e w i r e s embedded in the p l a s t i c o r e l e c t r i c
heating units attached to the m e t a l m o l d . It i s r e p o r t e d that, using this
s y s t e m , the t e m p e r a t u r e of the a i r in the autoclave r i s e s only 1 5 " to 2 0 "
above r o o m t e m p e r a t u r e with a mold s u r f a c e t e m p e r a t u r e of 3 0 0 " to 400" F.
Wood o r p l a s t e r molds a r e s o m e t i m e s used f o r e x p l o r a t o r y w o r k w h e r e only

a few p'ieces f a b r i c a t e d a t room t e m p e r a t u r e a r e r e q u i r e d .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
14.4. 1. 1 . 3 Bags o r Blankets. - - T h e purpose of the bag o r blanket is to
provide a flexible i m p e r m e a b l e b a r r i e r between the fluid under p r e s s u r e and
the mold. T h e piece being molded is p r e s s e d between this flexible bag and
the r i g i d s u r f a c e of the mold; t h e r e f o r e , the full fluid p r e s s u r e is applied at
right a n g l e s to the s u r f a c e of the p a r t r e g a r d l e s s of the s h a p e . T h e p r e s s u r e
at c e r t a i n points within c u r v e d p a r t s m a y , however, be slightly l e s s than the
full fluid p r e s s u r e by the amount n e c e s s a r y to shape o r f o r c e the facings o r
c o r e into place.
14-25
.. . .
_--

~ _ _ _ _ _ _ _ -
-~
MIL-HDBK-23A CHG N O T I C E 3 m 7777770 OLL18154 220 m
B a g s are c l a s s i f i e d as full bags o r blankets. A full bag i s a complete

envelope of i m p e r v i o u s flexible m a t e r i a l , completely closed and having only
a tube o r b l e e d e r connection f o r inflation o r evacuation. A blanket i s a s h e e t
t h a t n o r m a l l y fits the mold without wrinkling and is s e a l e d by s o m e t e m p o r a r y
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
m e a n s to its edges (fig. 14-14, A , B , and C). The b l e e d e r m a y be attached

e i t h e r to the mold o r to the blanket.
T h e useful life of a bag depends on the type of m a t e r i a l , the heating

m e d i u m u s e d , the t e m p e r a t u r e of the c y c l e , and the c a r e used in handling.
T h e type of bag m a t e r i a l depends l a r g e l y on the molding p r o c e s s , the t e m -
p e r a t u r e , and the heating medium. T h e u s e of s t e a m r e q u i r e s bags m a d e of
s p e c i a l l y compounded n a t u r a l o r synthetic r u b b e r . When hot air is u s e d ,
polyvinyl-alcohol f i l m , polyester f i l m , o r cellophane m a y be used and d i s -
c a r d e d a f t e r ode operation. Soft aluminum foil and s t a i n l e s s s t e e l foil have
been s u c c e s s f u l l y u s e d as bag m a t e r i a l s in s o m e e l e v a t e d - t e m p e r a t u r e m o l d -
ing o p e r a t i o n s .
Whenever a s t e a m - a i r m i x t u r e is u s e d and the a i r i s introduced under

p r e s s u r e f r o m a c o m p r e s s o r , an adequate a f t e r c o o l e r and a i r f i l t e r should
b e i n s t a l l e d between the c o m p r e s s o r and the cylinder. T h e life of a r u b b e r
bag is considerably i n c r e a s e d when all t r a c e s of oil in the f o r m of vapor o r
small d r o p s a r e r e m o v e d f r o m the air.
--_
When a r u b b e r b l e e d e r h o s e i s employed, i t m u s t not collapse and c l o s e
when e x t e r n a l p r e s s u r e is e x e r t e d upon it during the molding c y c l e . Collapse
of t h e b l e e d e r h o s e within the cylinder i s difficult to o b s e r v e . E m i s s i o n of a
slight amount of air o r s t e a m f r o m the b l e e d e r does n o t guarantee that it is
functioning p r o p e r l y . Flexible m e t a l h o s e , a copper tube, o r a suitably
r e i n f o r c e d r u b b e r hose is r e c o m m e n d e d f o r the b l e e d e r .
In using the method shown i n f i g u r e 14-14B, c a r e f u l attention should be

given t o t h e inside s u r f a c e of the b l e e d e r fitting in the bag. If this fitting i s
v e r y smooth and f l a t it m a y m a k e an a i r t i g h t fit and s t o p the bleeder f r o m
functioning. Grooves in this fitting, o r a piece.of c o a r s e b u r l a p o r s c r e e n
bonded to i t , will usually suffice.
1 4 . 4 . 1 . 1 . 4 P r e s s u r e and T e m p e r a t u r e Equipment. - - A l l p r e s s u r e equip-

m e n t f o r u s e with f l u i d - p r e s s u r e molding should be hydraulically t e s t e d to a
p r e s s u r e of at l e a s t double that of the m a x i m u m working p r e s s u r e to be used
o r in a c c o r d a n c e with s t a t e o r local c o d e s . An adequate safety valve should
always be installed if the s t e a m o r a i r i s drawn f r o m a supply line that is in
excess of the p r e s s u r e a t which the cylinder w a s t e s t e d .
14-26 _-

---
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 OLYB155 167 m
T h e devices placed within t h e p r e s s u r e cylinder f o r controlling and r e c o r d -

ing conditions should be c a r e f u l l y i n s t a l l e d . Heavily jacketed controls will
l a g and t h e r e f o r e w i l l not r e c o r d the a c t u a l cylinder t e m p e r a t u r e during the
r a p i d heating period. A jacketed t h e r m o m e t e r w a s found t o be a s much as
2 0 " t o 3 0 " F below t h e reading on a b a r e t h e r m o c o u p l e i n heating a cylinder
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
2 f e e t i n d i a m e t e r and 6 f e e t long t o 2 5 0 " F in 5 minutes with a s t e a m - a i r

m i x t u r e , T h e l a g would be much g r e a t e r i f a p o o r e r heating medium such a s
d r y air o r an i n e r t g a s w a s u s e d .
If t e m p e r a t u r e s t r a t i f i c a t i o n e x i s t s in t h e c y l i n d e r , a t e m p e r a t u r e r e c o r d -
ing bulb at t h e t o p of the cylinder m a y r e a d 3 0 " F o r m o r e above the t e m -
p e r a t u r e at the bottom of t h e c y l i n d e r . T h e r e f o r e , in o r d e r to m i n i m i z e
t e m p e r a t u r e s t r a t i f i c a t i o n , and to k e e p t h e r m o m e t e r readings m o r e a c c u r a t e ,
s o m e m e a n s of circulation should be provided. A good check on uniformity
of t e m p e r a t u r e m a y be obtained by i n s e r t i n g b a r e thermocouples i n the top
and bottom of t h e c y l i n d e r .
1 4 . 4 . 1 . 1 . 5 Amount of P r e s s u r e . - - T h e p r e s s u r e s u s e d in f l u i d - p r e s s u r e
molding of sandwiches v a r y f r o m a vacuum drawn on the bag to a maximum
of about 7 5 pounds p e r s q u a r e inch. Vacuum alone n o r m a l l y produces s u f -
f i c i e n t p r es s u r e f o r sandwich constructions involving contact - p r e s s u r e
laminating r e s i n s , but is insufficient f o r operations such a s bonding alumi -
num facings on end-grain b a l s a c o r e s . Sufficient p r e s s u r e should be used to
i n s u r e contact between c o r e and face s h e e t . In determining the p r o p e r
p r e s s u r e , consideration should be given to the p r e s s u r e l i m i t a t i o n s of the
c o r e as given i n t a b l e 1 4 - 1 . T h e s e values w e r e obtained between rigid s u r -
faces and t h e r e f o r e a r e integrated o r a v e r a g e values; w h e r e a s with the
u n i f o r m d i s t r i b u t i o n , c h a r a c t e r i s t i c of fluid p r e s s u r e , the w e a k e r spots in
t h e c o r e f a i l f i r s t . Considering t h e unavoidable nonuniformity of a l l c o r e
m a t e r i a l s , fluid molding p r e s s u r e s should not exceed approximately 50 per -
c e n t of the proportional-limit p r e s s u r e s of table 1 4 - 1 .
When fluid p r e s s u r e i s u s e d , a l l v a r i a t i o n s in thickness of c o r e , f a c i n g s ,

or a d h e s i v e s p r e a d r e s u l t in nonuniformities o r waviness in the facing next
I t o the blanket. I'nder s o m e f o r m s of loading, the s t r e s s e s on the c o r e - t o -
facing bond a r e proportional to the magnitude of t h e s e i r r e g u l a r i t i e s ; t h e r e -
f o r e , i t is i m p e r a t i v e to k e e p t h e s e i r r e g u l a r i t i e s to a m i n i m u m .
1 4 . 4 . 1. 1 . 6 Fluid P r e s s u r e A s s e m b l y J i g s . - - C o m p l e x sandwich p a r t s a r e
s o m e t i m e s a s s e m b l e d f r o m s u b a s s e m b l i e s by m e a n s of bonding i n f l u i d -
p r e s s u r e a s s e m b l y j i g s . T h e s e j i g s a r e often fabricated f r o m welded s t e e l
construction and h e a t e d e l e c t r i c a l l y o r by m e a n s of e l e c t r i c a l l y heated flexible
blankets. A typical f l u i d - p r e s s u r e a s s e m b l y jig of this type f o r a portion of a
sandwich wing is shown d i a g r a m m a t i c a l l y in f i g u r e 1 4 - 1 6 , w h e r e it i s shown
that because of the v a r i a t i o n of m a t e r i a l s being a s s e m b l e d , the j i g is s o made
that widely d i f f e r e n t p r e s s u r e s (compatible with the m a t e r i a l s being a s s e m b l e d )
a r e employed in t h e s a m e f i x t u r e .
!
1 4 -27
-

~ ~- ~
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 OL4L.56 O T 3 W
14.4.1.2 Rigid Dies
Molding o r bonding p r e s s u r e i s often applied to sandwich panels by

p r e s s i n g t h e m between s u r f a c e s m a d e of m e t a l o r s o m e o t h e r rigid m a t e r i a l .
The f o r c e is n o r m a l l y applied by a hydraulic piston o r s c r e w t h r e a d s , and
s t o p s m a y be u s e d i n s o m e c a s e s to obviate c r u s h i n g of the c o r e . In using
s t o p s , c o r e t o l e r a n c e s and bonding p r e s s u r e s should be carefully c o n s i d e r e d
t o i n s u r e the integrity of the completed p a r t .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
T h e s i m p l e s t f o r m of rigid-die application is the conventional hydraulic
p r e s s . Stops between the platens a r e s o m e t i m e s n e c e s s a r y to avoid o r con-
t r o l c o m p r e s s i o n of s o m e of the w e a k e r s t o p s , but many of t h e s e f l a t panels
have an edge banding of d e n s e r m a t e r i a l that s e r v e s the s a m e p u r p o s e s a s
stops.
In using a multiple-opening hot p r e s s , the panels

in e a c h of the openings m u s t be identical i n s i z e ,
s h a p e , and p r e s s u r e r e q u i r e m e n t s ; f u r t h e r m o r e ,
they m u s t be located in the s a m e position a s
identical a s s e m b l i e s in a l l of the o t h e r openings
in u s e in one p r e s s load.
To avoid nonuniform p r e s s u r e on f l a t sandwich p a n e l s , the platens of a

hot p r e s s m u s t be exceedingly a c c u r a t e , and the thickness t o l e r a n c e s of a l l
of the component p a r t s i n the sandwich m u s t be within c l o s e l i m i t s . Because
t h i s is often i m p r a c t i c a l , it is s o m e t i m e s n e c e s s a r y to i n s e r t tooling to s u p -
ply fluid p r e s s u r e t o one s i d e of the sandwich being molded. One method of
doing this is shown i n figure 14-17, which involves the u s e of a thin, o i l -
filled m e t a l b l a d d e r , The u s e of o i l , o r s o m e o t h e r high-boiling-point liquid,
is p r e f e r r e d o v e r a i r b e c a u s e the liquid i s noncompressible and t r a n s m i t s
h e a t m u c h m o r e effectively than a i r . The e s s e n t i a l s t e p s in fabricating an
oil-filled m e t a l bladder a r e a l s o shown i n f i g u r e 14-17.
A s e t of mating rigid dies f o r a c u r v e d sandwich p a r t n o r m a l l y r e p r e s e n t s

a c o n s i d e r a b l e investment b e c a u s e of the a c c u r a c y of f i t r e q u i r e d . In addi-
tion they m a y b e c o m e d i s t o r t e d f r o m repeated u s e and t e m p e r a t u r e changes.
Consequently, they a r e u s e d only f o r l a r g e quantities of p a r t s f o r which
e x a c t specifications as to s i z e , t h i c k n e s s , and shape have been established.
T o expedite production, heated dies a r e c o m m o n and, i f production schedules
d i c t a t e , cooling of the dies m a y be r e q u i r e d in s o m e c a s e s . T h e method of
heating will depend upon the s i z e of the d i e s , r a t e of heating r e q u i r e d , o r
availability of equipment and m a y be supplied externally by conduction i n a
hot p r e s s , o r internally by s t e a m , hot w a t e r , o r e l e c t r i c i t y . C a s t a l u m i -
num dies having e x t e r n a l copper heating t u b e s , m e t a l - s p r a y e d in place,
have a l s o been used.
14-28
-

~- ~
____ - _ _ - __
MIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 0148157 T 3 T W
T h e a c t u a l magnitude of the p r e s s u r e applied on any point i n a sandwich

p a r t between a s e t of c u r v e d dies is subject to s o m a n y v a r i a b l e s that i t is
seldom known. C u r v a t u r e of the p a r t , thickness uniformity, modulus of
e l a s t i c i t y of the c o r e m a t e r i a l , and a c c u r a c y of the d i e s all affect the p r e s -
s u r e applied at any specific point. Optimum conditions m a y b e d e t e r m i n e d
by c a r e f u l inspection and d e s t r u c t i v e testing of s e v e r a l e x p l o r a t o r y p a r t s
m a d e a t calculated p r e s s u r e s ranging f r o m inadequate contact to definite
c r u s h i n g of the c o r e .
Production e x p e r i e n c e with rigid die bonding has indicated that its s u c -

c e s s f u l u s e r e q u i r e s e x t r e m e l y a c c u r a t e tooling, (and subsequent checking
f o r a c c u r a c y ) and c l o s e thickness t o l e r a n c e s on the component p a r t s f o r m -
ing t h e sandwich a s s e m b l y being bonded; t h e r e f o r e its u s e is not generally
r e c o m m e n d e d on s t r u c t u r a l sandwich a s s e m b l y .
14.4. 1 . 3 S e m i r i g i d Dies
-
P l a t e n s o r dies having one o r both mating s u r f a c e s somewhat r e s i l i e n t
a r e s o m e t i m e s u s e d to s i m u l a t e f l u i d - p r e s s u r e molding. T h e r e s i l i e n t s u r -
f a c e s provide a m o r e uniform distribution of p r e s s u r e than do rigid s u r f a c e s ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
without r e s o r t i n g to the u s e of a fluid u n d e r p r e s s u r e . The h a r d n e s s of the
r e s i l i e n t l i n e r o r caul is d e t e r m i n e d by the c h a r a c t e r i s t i c s of the sandwich
p a r t being p r e s s e d . If it is too h a r d o r soft, it w i l l not produce the d e s i r e d
r e s u l t s . T h e m o s t suitable m a t e r i a l can usually b e d e t e r m i n e d only by t r i a l ,
F o r example, a s o f t - t e x t u r e d wool blanket was found s a t i s f a c t o r y f o r p r e s s -
ing g l a s s - f a b r i c facings on e n d - g r a i n b a l s a c o r e s a t 15 pounds p e r s q u a r e
inch, while 1/ 8 - i n c h cotton-duck pads w e r e n e c e s s a r y f o r bonding aluminum
facings to e n d - g r a i n b a l s a c o r e at 300 pounds p e r s q u a r e inch. Rubber,
chipboard, p a p e r , and felt have a l s o found u s e .
A r e s i l i e n t pad u s e d on only one s i d e of a sandwich r e s u l t s ir, one s m o o t h

s u r f a c e (next to the d i e ) , and in one i r r e g u l a r s u r f a c e that conforms roughly
t o the thickness v a r i a t i o n s of the c o r e . Resilient pads u s e d on both s u r f a c e s
r e s u l t in slight i r r e g u l a r i t i e s i n both s u r f a c e s of the p a r t . F o r sandwich
p a r t s exposed to the a i r s t r e a m , smooth s u r f a c e s a r e e s s e n t i a l , and, t h e r e -
.
f o r e only one r e s i l i e n t pad c a n be u s e d ; w h e r e a s , f o r i n t e r n a l sandwich s t r u c -
t u r e s , s u c h as f l o o r s , p a r t i t i o n s , o r s h e a r w e b s , one o r two pads m a y b e
used.
A p r o c e s s similar to "hydropressing" of m e t a l might be u s e d f o r slightly

c u r v e d sandwich p a r t s by forcing a soft r u b b e r plug of the p r o p e r s h a p e into
a heated die,
. . 14-29

=
~
MIL-HDEK-23A CHG N O T I C E 3 W 9999970 0148158 976
14.4.1.4 Expanding C o r e s
P r e s s u r e is applied by the c o r e itself when foamed-in-place c o r e s a r e

used. T h e s e sandwiches r e q u i r e no externally applied p r e s s u r e but instead
a r e s t r a i n i n g m o l d t h a t supplies the r e q u i r e d h e a t to expand and c u r e the
core.
With laminated facings of g l a s s f a b r i c and foamed-in-place c o r e s , the

facings a r e molded f i r s t , usually on a s e t of m a l e and female heated dies
employing fluid p r e s s u r e applied through a bag o r blanket. With the facings
i n p l a c e , the u n c u r e d liquid c o r e m i x t u r e i s poured into the f e m a l e mold
and the m a l e mold is quickly lowered and clamped i n place. The c o r e m a t e -
rial then expands and is finally c u r e d by application of h e a t to f o r m the bond
between the c o r e and facings. To i n s u r e a good bond between facings and
c o r e , the facings m u s t be clean and f r e e f r o m any contamination, s u c h a s
m o l d - r e l e a s e a g e n t s . One method commonly u s e d is t o s a n d t h e facings
lightly, but c a r e m u s t be e x e r c i s e d to i n s u r e that t h e g l a s s f i b e r s a r e not
exposed. A c r o s s - s e c t i o n a l s k e t c h of a s e t of dies of this type is shown in
f i g u r e 14-18.
14.4.2 Techniaues f o r Curved P a r t s

-.
Parts of single o r compound c u r v a t u r e are s o m e t i m e s m a d e by the s a m e
methods as a r e u s e d on flat p a r t s but, f o r c e r t a i n combinations and d e g r e e s
of c u r v a t u r e , s p e c i a l techniques a r e r e q u i r e d .
1 4 . 4 . 2 . 1 Single C u r v a t u r e
Parts with only slight single c u r v a t u r e can readily be molded by m e r e l y

draping the c o r e and facings i n a concave mold and l a t e r applying p r e s s u r e
by m e a n s of a blanket o r a mating die. An a s s e m b l y of this kind, utilizing
a thin s t e e l mold and fluid p r e s s u r e e x e r t e d through a b a g , is shown in
f i g u r e 14-14B.
A s the c u r v a t u r e b e c o m e s m o r e s e v e r e , it b e c o m e s m o r e difficult to
bend the c o r e t o s h a p e and t o draw it down f i r m l y to the mold s u r f a c e s . T h e
a n t i c l a s t i c (saddle-shaped) c u r v a t u r e , which m o s t c o r e m a t e r i a l s tend to
a s s u m e upon bending, c a u s e s s o m e difficulty even a t m o d e r a t e c u r v a t u r e .
This c h a r a c t e r i s t i c is p a r t i c u l a r l y noticeable with honeycomb c o r e s . The
limitations i m p o s e d on c u r v a t u r e s of c o r e m a t e r i a l s by their tendency t o
a s s u m e a n a n t i c l a s t i c c u r v a t u r e v a r y with the thickness and type of c o r e
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
and have not been fully investigated,
~-
14-30

MIL-HBBK-23A CHG N O T I C E 3 9999970 03481159 0 2
Often the s e v e r i t y of c u r v a t u r e t o which a panel can be molded by the

"draping method, ' I o r o n e - s t e p molding p r o c e s s , is limited by breakage of
.the c o r e m a t e r i a l i n bending. An attempt to evaluate this limitation was
m a d e by determining the approximate breaking radius of 1 -inch-\vidc- s t r i p s
of four typical c o r e m a t e r i a l s i n a v a r i e t y of t h i c k n e s s e s f r o m one-eighth to
one-half inch. If a f a c t o r of safety against b r e a k a g e of about 2 would be
applied to t h e s e r a d i i , it was believed that reasonably s a f e working radii
would r e s u l t . T h e s e working r a d i i have been investigated in an exploratory
m a n n e r by bending l a r g e r s h e e t s of c o r e m a t e r i a l between thin s h e e t s of
aluminum, and r e s u l t s a r e listed below. This tabulation m a y be used in
e s t i m a t i n g a n approximately s a f e working radius f o r typical c o r e m a t e r i a l s
in fabricating c u r v e d p a r t s by the draping method.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Thickness of c o r e Radius in inches

in inches
118 6
3/16 11
114 18
5/16 24
318 32
7/16 40
112 50
If it is d e s i r e d to m a k e c u r v e d sandwich panels having r a d i i s m a l l e r

than the s a f e working r a d i i l i s t e d above, s p e c i a l m e a n s of forming the
c o r e m u s t be employed. S o m e of the s u p p l i e r s of c o r e m a t e r i a l can supply
p r e f o r m e d c o r e to specifications. S o m e c o r e m a t e r i a l s , such a s paper
honeycomb, lend t h e m s e l v e s somewhat to postforming while hot. Another
method, p e r h a p s l e s s c u m b e r s o m e , is to bond o r laminate one facing to the
c o r e i n the f i r s t operation, to bend the a s s e m b l y to approximately the proper
shape (with the faced s i d e a s the convex s i d e ) , and then bond the i n n e r facing
to t h e c o r e in a second molding operation. A s i m i l a r a l t e r n a t e p r o c e d u r e
is i l l u s t t a t e d in figure 14-19. Fundamentally, this p r o c e s s is the s a m e a s
t h a t u s e d i n steam-bending wood with a m e t a l tension band. The c o r e m a t e -
rial to be bent is positioned between two stops on the tension s h e e t and bent
o v e r a f o r m of the p r o p e r shape s o that the m e t a l s h e e t takes a l l of the t e n -
s i o n s t r e s s e s and the c o r e is deformed by c o m p r e s s i o n .
14-31

-__ - .- --
MIL-HDBK-2ZA CHG NOTICE 3 9999970 0148160 5 2 4
14.4.2.2 Compound C u r v a t u r e
T h e amount of compound c u r v a t u r e that c a n b e f o r m e d in a sandwich

p a r t without r e s o r t i n g t o s p e c i a l techniques is l i m i t e d by the facings, the
c o r e , o r both. In addition, the r e l a t i o n of the r e s p e c t i v e c u r v a t u r e s in
i n t e r s e c t i n g planes m a y have a n effect on the details and r e l a t i v e e a s e of
fabrication; i n g e n e r a l , panels having appreciable compound c u r v a t u r e p r e -
s e n t difficult fabricating problems. C e r t a i n combinations of m a t e r i a l s ,
s u c h as g l a s s - f a b r i c facings wet-laminated to a g l a s s - f a b r i c honeycomb
c o r e , accommodate compound c u r v a t u r e m o r e readily than do o t h e r s , s u c h
as aluminum facings bonded t o honeycomb c o r e s .
Parts having only a v e r y m o d e r a t e amount of compound c u r v a t u r e m a y

be m a d e by the o n e - s t e p p r o c e s s i n the s a m e m a n n e r a s flat p a r t s o r p a r t s
having m o d e r a t e single c u r v a t u r e . If possible, the c o r e should b e p r e p a r e d
as a single s h e e t and l a i d i n place between the facings; but i f the stiffness of
the c o r e is the limiting f a c t o r , it m a y b e t a i l o r e d in place f r o m small pieces.
No t e s t s , o t h e r than by trial, a r e available f o r guidance as to the m a x i m u m
c u r v a t u r e feasible.
F o r s e v e r e compound c u r v a t u r e s , o n e - , two-, o r t h r e e - s t e p fabricating

p r o c e s s e s m a y b e indicated. G l a s s - f a b r i c facings on g l a s s - f a b r i c honey-
comb c o r e s can n o r m a l l y be l a i d and molded in a single operation, u n l e s s
f o r s o m e r e a s o n , s u c h as to m i n i m i z e air bubbles i n the f a c i n g s , i t is n e c e s - -_
s a r y to mold the facings s e p a r a t e l y . When foamed-in-place c o r e s a r e u s e d ,
t h e f a b r i c a t i o n is i n two s t e p s : (1) F a c i n g s , usually of g l a s s - f a b r i c - r e i n f o r c e d
p l a s t i c , a r e f o r m e d on m a l e o r f e m a l e molds o r between mating d i e s , and
(2) c o r e is poured and c u r e d between the facings (held in p r o p e r position by
dies as shown i n f i g u r e 14-18) thus forming t h e sandwich p a r t . O t h e r c o m -
binations, s u c h as aluminum facings on b a l s a c o r e , r e q u i r e a t h r e e - s t e p
p r o c e s s : ( i ) F o r m i n g the facings, (2) preforming the c o r e , and ( 3 ) bonding
the facings t o t h e c o r e . Aluminum facings m a y be f o r m e d by a carefully
controlled s t r e t c h i n g technique. B a l s a c o r e s of compound c u r v a t u r e s a r e
produced by building up the d e s i r e d s h a p e , o r by dampening one s u r f a c e ,
and then drying the c o r e in the p r o p e r l y c u r v e d position.
14.4.3 Mold-Release Agents
S o m e m e a n s of insuring e a s y r e m o v a l of the p a r t f r o m the mold m u s t be

provided to avoid damage to the p a r t being f o r m e d and to the mold.
14-32
-.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~-
MIL-HDBK-23A CHG N O T I C E 3 9999970 OL48LbL 4 6 0
Metal fac.ings next to mold o r caul s u r f a c e s of m e t a l p r e s e n t no problem

i f both s u r f a c e s a r e clean and f r e e f r o m adhesive squeeze-out. However,
i f the m e t a l facings include j o i n t s , adhesive m a y squeeze through and f o r m
a bond u n l e s s adequate mold t r e a t m e n t is provided. In this c a s e , a v e r y
thin film of wax applied d i r e c t l y by wiping o r in a solution is adequate p r o -
tection against sticking.
T o m i n i m i z e warping and d i s t o r t i o n of l a r g e aluminum-faced sandwich

panels f o r m e d on s t e e l m o l d s , a m o l d - r e l e a s e agent o r lubricant is beneficial
and is s o m e t i m e s a n e c e s s i t y . E x t r e m e caution should b e e x e r c i s e d i n using
silicone r e l e a s e agents in production shops b e c a u s e of the possibility of
unde t e c t e d t r a n s fe r and contamination.
G l a s s - f a b r i c facings of compound c u r v a t u r e r e q u i r e the u s e of mold-

r e l e a s e coatings, r a t h e r than s h e e t s , in o r d e r to avoid the i m p r i n t s of
unavoidable w r i n k l e s . P a r t s a r e s o m e t i m e s r e l e a s e d f r o m polished m e t a
molds without the u s e of a coating, but f o r i n s u r a n c e against sticking, a
coating is recommended. Mold- r e l e a s e coatings of v a r i o u s types a r e being
u s e d , and no g e n e r a l recommendations c a n be m a d e f o r a l l resirr and mold
combinations. T h e final choice can b e s t be m a d e a f t e r a few exploratory
t e s t s . This is a l i s t of commonly used m o l d - r e l e a s e coatings;
Liquid o r paste wax

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Silicone r e s i n
Vegetable lecithin
Methyl cellulose
Polyvinyl alcohol l a c q u e r
Cellulose a c e t a t e butyrate dope
Aluminum o r zinc s t e a r a t e
Polyvinyl f lu0 r i de s
Since m o s t of t h e s e coatings a r e applied as v e r y thin f i l m s to avoid

possible contamination of the r e s i n , the molds m u s t b e highly polished to
obviate m e c h a n i c a l adhesion. In s o m e c a s e s a combination of two coatings
h a s been found n e c e s s a r y . W h e r e the s u r f a c e is subsequently to b e painted
with r a i n - e r o s i o n - r e s i s t a n t coating o r o t h e r protective coating, mold-
r e l e a s e agents containing silicone should not be u s e d . In p a r t s that a r e to
b e subsequently p r o c e s s e d , s u c h a s premolded f a c e s f o r sandwich, any
m o l d - r e l e a s e agent m u s t be completely removed to i n s u r e a n adequate bond.
14-33

~ -~ _ _ _ ~-
MIL-HDBK-23A C H G N O T I C E 3 9999970 0148162 3 T 7 m
14.4.4 Attachment Details
All sandwich p a r t s m u s t be attached to the f r a m e w o r k of the a i r f r a m e

and often t o o t h e r s i m i l a r p a r t s ; t h e r e f o r e , m e a n s f o r t r a n s f e r r i n g the con-
c e n t r a t e d s t r e s s e s imposed a t these a t t a c h m e n t s m u s t be provided. O c c a -
sionally, on v e r y lightly s t r e s s e d p a r t s , u n r e i n f o r c e d bolt holes o r s u b s e -
quently i n s e r t e d r e i n f o r c e m e n t s w i l l suffice, but in m o s t s t r u c t u r a l applica-
tions l o c a l r e i n f o r c e m e n t s m u s t be i n c o r p o r a t e d during fabrication.
14.4.4.1 Edge R e i n f o r c e m e n t s and Doublers
Sandwich p a r t s a r e n o r m a l l y joined o v e r a f r a m i n g m e m b e r , and i t i s

common p r a c t i c e to i n c o r p o r a t e a continuous -edge r e i n f o r c e m e n t t o facilitate
the t r a n s f e r of s t r e s s e s . T h e r e a r e many ways of accomplishing s a t i s f a c t o r y
edge reinforcing s o that s u c h details a s loads to be t r a n s f e r r e d , type of f a c -
ings and c o r e , a t t a c h m e n t fittings, and i m p o r t a n c e of s m o o t h n e s s of s u r f a c e ,
should be c o n s i d e r e d b e f o r e selection i s m a d e . Typical edge r e i n f o r c e m e n t s
f o r aluminum-faced and g l a s s - f a b r i c - f a c e d p a r t s a r e shown in figure 14-20.
A r e a s of c r u s h e d low-density honeycomb c o r e should be r e s i n stabilized to
prevent disintegration u n d e r sonic environment.
Some edge t r e a t m e n t s s e r v e a s an effective m o i s t u r e s e a l in addition to

providing r e i n f o r c e m e n t . O t h e r s depend upon edge coating to s e a l out m o i s -
t u r e and m i s c e l l a n e o u s a i r f r a m e fluids ( r e f . 14-6). H i g h - s t r e n g t h i n s e r t s
m a y be of a v a r i e t y of m a t e r i a l s , including e n d - g r a i n mahogany o r s p r u c e ,
plywood (flat o r on edge), o r reinforced p l a s t i c s . Additional bolt-bearing
a r e a may be provided by r e i n f o r c e m e n t s o r by i n c r e a s i n g f a c e t h i c k n e s s .
14.4.4.2 Doublers and I n s e r t s
The design of a sandwich s t r u c t u r e m a y be s u c h that loads m u s t be

t r a n s f e r r e d t o o r f r o m individual p a r t s a t points o t h e r than a t t h e i r edges.
I n s e r t s in the p a r t a r e r e q u i r e d a t t h e s e a t t a c h m e n t points i f the loads a r e
of appreciable magnitude, s u c h a s o v e r wing r i b s o r fuselage bulkheads.
Typical i n s e r t s a r e p r e s e n t e d in figure 14-2 1. T h e s e m a y be in the f o r m of
s t r i p s , i n s e r t e d continuously a c r o s s the panel, o r a s l o c a l r e i n f o r c e m e n t s
u n d e r individual bolt fittings. S h e a r loads on a t t a c h m e n t bolts m a y r e q u i r e
additional r e i n f o r c e m e n t , a s shown i n figure 14-2 l B , t o provide adequate
bolt-bearing a r e a . F i g u r e 14-22A shows one method of densification of
m e t a l honeycomb by m e a n s of i n s e r t s . Densification by c o m p r e s s i n g the
c o r e of m e t a l honeycomb, a s shown i n figure 14-22B, i s another method
s o m e t i m e s employed.
14-34
--
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~-
- ____.___-
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 01481b3 2 3 3 =

14.4.4.3 Cut-Outs
Openings in sandwich p a r t s f o r inspection, f i l l e r h o l e s , o r adjustment

of fittings m u s t often be provided. T e s t s have d e m o n s t r a t e d t h a t , with Cer-
t a i n r a t i o s of opening to panel s i z e , t h e r e i s a concentration of s t r e s s around
t h e cut-outs t h a t m a y r e q u i r e consideration i n design.' E x p e r i e n c e has shown
that t h e s e i n c r e a s e d s t r e s s e s can often be c a r r i e d by high-strength c o r e
i n s e r t s o r ed.ge t r e a t m e n t s around the opening, a s shown in figure 14-20. If
the cut-out r e q u i r e s a c o v e r , the m e a n s of attachment m u s t be considered
i n choosing the p r o p e r edge r e i n f o r c e m e n t around the cut-out.
14.4.4.4 Joints i n Facings
P a r t s i z e s in e x c e s s of available facing widths m a k e joints in the facings

a n e c e s s i t y . This p r e s e n t s no p a r t i c u l a r difficulty with g l a s s f a b r i c , a s the
individual s h e e t s m a y b e overlapped slightly during lay-up. Overlaps should
b e s t a g g e r e d s o t h a t no m o r e than one is p r e s e n t in any c r o s s s e c t i o n , includ-
ing any joints in the c o r e .
Facing m a t e r i a l s of the s h e e t type, s u c h a s m e t a l , m u s t be joined when

l a r g e s i z e s a r e r e q u i r e d . Since the type and quality of joint is dictated by
the application, s o m e m u s t of n e c e s s i t y be flush while o t h e r s will p e r m i t a
projection f r o m the s u r f a c e . S o m e joints a r e i l l u s t r a t e d in figure 1 4 - 2 3
w h e r e both A and B m a y be u s e d f o r m e t a l facings and differ only in the
location of the butt plate. I n t e r n a l butt plates a r e r e q u i r e d f o r a l l e x t e r i o r
facings exposed t o the air s t r e a m , while e x t e r i o r butt plates a r e p r e f e r r e d ,
b e c a u s e of s i m p l i c i t y , f o r a l l unexposed s u r f a c e s .
14.4.4.5 Attachment Fittings
Sandwich p a r t s a r e attached by m e a n s of bolts o r s c r e x s . A c c e s s o r i e s ,

s u c h as , s h e l v e s , fittings, and mounting b r a c k e t s , a r e often fastened t o the
p a r t s by the s a m e m e a n s . Inspection-door c o v e r s a r e s o m e t i m e s fastened
by m e a n s of s p e c i a l quick-opening fittings. Most of t h e s e attachment fittings
r e q u i r e holes through the panel, usually specially p r e p a r e d to fit the attach-
m e n t o r adaptor.
A few m i s c e l l a n e o u s types of attachment fittings f o r m e t a l - f a c e d s a n d -

wich p a r t s a r e shown i n figure 14-24. Whenever i n s e r t s , s l e e v e s , o r
bushings a r e employed, t o l e r a n c e s on the p a r t thickness m u s t be carefully
maintained to i n s u r e p r o p e r f i t .
14-35
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

___
NIL-HDBK-23A CHG NOTICE 3 = 9999970 OL48364 L7T
It is g e n e r a l l y c o n s i d e r e d good p r a c t i c e to u s e a t t a c h e m e n t fittings that

d i s t r i b u t e the load t o both facings r a t h e r than t h o s e that a t t a c h to one facing
only. Lightly s t r e s s e d a t t a c h m e n t s on n o n s t r u c t u r a l p a r t s a r e exceptions,
as a r e a t t a c h m e n t s s o designed that they apply no cleavage s t r e s s e s to the
facing. O c c a s i o n a l l y , a t t a c h m e n t fittings of the latter type a r e bonded t o
one facing by a m e t a l - t o - m e t a l adhesive. F i g u r e 14-25 shows a fitting of
this type.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
S o m e of the a t t a c h m e n t methods shown in f i g u r e 14-24 m a y a l s o be

employed on sandwich panels having g l a s s -cloth facings; however, b e c a u s e
of t h e c h a r a c t e r i s t i c s of t h e s e facings, s p e c i a l types of a t t a c h m e n t s that
employ bonded joints a r e often p r e f e r r e d .
14.4.5 Trimming
Parts, a f t e r fabrication, often r e q u i r e t r i m m i n g and subsequent c l e a n -

ing t o a c h i e v e final dimensions and to r e m o v e rough e d g e s , adhesive
s q u e e z e - o u t , o r r e s i n flash. The t r i m m e d p a r t s r e q u i r e c a r e f u l handling
to p r o t e c t s h a r p c o r n e r s and edges f r o m d a m a g e . F i g u r e 14-26 i l l u s t r a t e s
one method of protecting c o r n e r s of t r i m m e d p a r t s b e f o r e final a s s e m b l y on
the aircraft.
Countersunk bolts a r e often not sufficiently s m o o t h f o r high-speed

p e r f o r m a n c e . Bolts of this type a r e machined a f t e r f a b r i c a t i o n by shaving
with a s p e c i a l tool.
1 4 . 4 . 6 Safety P r e c a u t i o n s
T h e f a b r i c a t i o n of sandwich c o n s t r u c t i o n s r e q u i r e s m a n y o p e r a t i o n s that,
if n o t p r o p e r l y s u p e r v i s e d , could be h a z a r d o u s , IV g e n e r a l , the s a f e t y p r e -
cautions specified and employed by the paint and v a r n i s h i n d u s t r y should be
followed, but w h e r e l o c a l codes e x i s t they should be o b s e r v e d whenever
applicable. E a c h operation m u s t be analyzed, and protection provided, i f
n e c e s s a r y , a g a i n s t f u m e s , v a p o r s , d u s t , s k i n infections, f i r e , and explosion.
Solvents s u c h as benzene, toluene, m e t h y l alcohol, c a r b o n t e t r a c h l o r i d e ,

and t r i c h l o r o e t h y l e n e that a r e u s e d in cleaning m e t a l s , thinning a d h e s i v e s ,
and washing equipment a r e toxic, and adequate ventilation m u s t be provided
to r e d u c e the concentration of solvent v a p o r s to l e s s than 2 0 0 p a r t s p e r
m i l l i o n p a r t s of air. F u m e s o r m i s t s f r o m c h e m i c a l cleaning solutions
should b e drawn into hoods so t h a t t h e s e c h e m i c a l s cannot b e inhaled o r
c o m e in contact with the skin.
14-36

____- ~ _ _ _ _ _ _ _
MIL-HBBK-23A CHG .NOTICE 3 9997970 OL48L65 006 =

c
Commonly u s e d r e s i n s of the phenolic and polyester types a r e not
c o n s i d e r e d generally toxic, but c e r t a i n individuals s e e m t o be a l l e r g i c to
t h e s e m a t e r i a l s , as evidenced by skin e r u p t i o n s , sinus infections, o r run-
ning e y e s , and m u s t be relieved of any contact with the aggravating m a t e r i a l .
Dusts that a r e f o r m e d as a r e s u l t of machining plastic p a r t s should be

removed by an effective exhaust s y s t e m ; in addition, r e s p i r a t o r s should be
w o r n when d u s t p a r t i c l e s capable of causing lung infection a r e p r e s e n t .
S o m e of the d u s t s f r o m g l a s s - f a b r i c and phenolic l a m i n a t e s a r e i r r i t a t i n g to
t h e skin and r e q u i r e the u s e of protective skin c r e a m s to prevent i r r i t a t i o n ,
D e r m a t i t i s m a y a l s o be caused f r o m contact with s o m e of t h e solvents and
a d h e s i v e s ; t h e r e f o r e , r u b b e r gloves should be w o r n when experience h a s
d e m o n s t r a t e d the need f o r protection.
E m p h a s i s should be placed on p e r s o n a l c l e a n l i n e s s a s a g e n e r a l p r e c a u -
tion against d i s c o m f o r t f r o m skin infection. Clothes should be changed
a f t e r e a c h shift and hands washed frequently to remove dangerous accumula-
tions of i r r i t a t i n g m a t e r i a l s .
Many of the solvents employed a r e highly inflammable; t h e r e f o r e ,

s t a n d a r d precautions f o r s t o r a g e and u s e of inflammable m a t e r i a l s m u s t be
enforced. Benzoyl peroxide, a c a t a l y s t u s e d with m a n y of the p o l y e s t e r -
type r e s i n s , is a l s o highly inflammable in the d r y powder f o r m and c a r e
should be taken that this c h e m i c a l is s t o r e d in a cool place and that it i s not
subjected to any h e a t , such a s the f r i c t i o n of grinding.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
T e s t s have shown that paint r e m o v e r s used on
bonded panels w i l l diffuse into the edges of the
bonds and d i s i n t e g r a t e m o s t s t r u c t u r a l adhesives.
14.4.7 SDecifications
T h e f a b r i c a t i o n of completed sandwich p a r t s c a n b e s t be controlled by

m e a n s of c l e a r , concise p r o c e s s and m a t e r i a l specifications. Since the
s i z e and u s e to which sandwich constructions a r e put v a r y widely, it is
e s s e n t i a l t h a t the specifications should control all s t a g e s of manufacturing
define plus o r minus l i m i t s w h e r e they a r e r e q u i r e d , and specify acceptab e
m a t e r i a l s to be u s e d d i r e c t l y o r indirectly in the f a b r i c a t i o n p r o c e s s .
14-37
----------- -
-..
- _-
~
.-. . _

NIL-HDBK-23A CHG N O T I C E 3 m 7999970 014Lbb T 4 2 H
(14- 1) BURROWS, C. F.
1957. Development of B r a z e d Sandwich Construction f o r High T e m -
p e r a t u r e Applications. IN S t r u c t u r a l Adhesives and Sandwich
Construction, Wright A i r Develop. C e n t e r T e c h . Rep. 57-513.
( 14 -2) DOW CKEMICAL COMPANY

1955. Magnesium F i n i s h i n g .
(14-3) EICKNER, H. W.
1954-55. Adhesive Bonding P r o p e r t i e s of Various M e t a l s a s Affected
by C h e m i c a l and Anodizing T r e a t m e n t s of t h e S u r f a c e s . U . S.
F o r e s t P r o d , Lab. Rep. 1842, RevisFd A p r i l 1954; P a r t A,
F e b r u a r y 1955.
(14-4) EICKNER, H. W .
1958. E f f e c t of S u r f a c e T r e a t m e n t on t h e Adhesive Bonding P r o p e r t i e s
of Magnesium. U.S. F o r e s t P r o d . L a b . Rep. 1865,.
(14-5) EICKNER, H. W. AND SCHOWALTER, W . E .

1950. A Study of Methods f o r P r e p a r i n g Clad 24STT3 Aluminum-
Alloy Sheet S u r f a c e s f o r Adhesive Bonding. U.S. F o r e s t -_
P r o d . Lab. Rep, 1813. P a r t s 1-11, May; Part III, D e c e m b e r .
(14-6) HEEBINK, B. G.
1956. M o i s t u r e - E x c l u d i n g E f f e c t i v e n e s s of E d g e S e a l s f o r A i r c r a f t
Sandwich P a n e l s . U.S. F o r e s t P r o d . Lab. Rep. 1822.
(14-7) LEWIS, W . J . , FAULKNERy G. E . , AND R I E P P E L , P. J .

1957. S t a i n l e s s S t e e l and T i t a n i u m S t r u c t u r e s Titanium
M e t a l l u r g i c a l Lab. Rep. 7 9 , B a t t e l l e M e m o r i a l I n s t i t u t e ,
(14-8) MERRIMAN, H. R .
1957. R e s e a r c h on S t r u c t u r a l Adhesive P r o p e r t i e s O v e r a Wide
T e m p e r a t u r e Range. Wright A i r Develop. C e n t e r T e c h .
Rep. 56-320.
(14 -9) MUNCHNICK, S . N . AND OTHERS.

1955-57. T r e a t m e n t of M e t a l S u r f a c e s f o r Adhesive Bonding. W r i g h t
A i r Develop, C e n t e r T e c h . Rep. 55-87, P a r t s I through V I .
F r a n k l i n Ins titute.
14-38
...
-----....
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-- - -.
MIL-HDBK-23A CH6 N O T I C E 3 9999970 OL48Lb7 99

Current Adhesive Bonding, P r o c e s s and Inspection R e q u i r e m e n t s F o r
U . S . M i l i t a r y Specification MIL-A-9067

Current Magnesium Alloy, P r o c e s s e s f o r P r e t r e a t m e n t and P r e v e n t i o n
of C o r r o s i o n On. U . S . M i l i t a r y Specification MIL-M-3 17 1

Current P r i m e r Coating, Zinc C h r o m a t e , Low-Moisture -Sensitivity.
U . S . M i l i t a r y Specification M I L - P - 8 5 8 5 .
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14-39

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NIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0348369 751
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Figure 1 4 - 1 . --Typical core section of aluminum honeycomb fabricated from

pr eco r rugated perforated aluminum foil.
M 110456
c

~ - - -~-- .
-
MIL-HBBM-23A C H G N O T I C E 3 W 9979970 0148170 473 W
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----- -_
MIL-HDBK-23A C H G N O T I C E 3 E 9999970 Ol148l17L 3 0 T W
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Figure 14-3. --Upper, high speed router shown cutting aluminum honeycomb
c o r e s ; lower, cutters used for the undercutting of aluminum honeycomb
cores.
M 133 053

MIL-HDBK-23A C H G N O T I C E 3 m 9999970 OL48L72 2Yb W
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Figure 14-4. - - P r e c u t blocks of m e t a l honeycomb c o r e being placed in

reusable containers for temporary storage.
M 110 968

- - ~ ~ _ _
MIL-HDBK-23A C H G N O T I C E 3 W 9999970 03481173 3 8 2
Figure 14-5. --An electrolytic discharge surfacing operation in action. The

wheel does not actually touch the stainless steel honeycomb core. The
operation is similar to plating except in reverse; the electr.olyte dis-
integrates the metal, A planer modified as shown can be used to advantage
in the surfacing operation. The finished surface is burr-free and the thick-
*
ness tolerance can be held to 0.002 inch.
M 113 535
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y
- -~ __ -_
MIL-HDBK-23A CHG N O T I C E 3 E 9999970 0148174 019 E
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Figure 14-6. --Dial indicator with special base affords a convenient means of
checking the thickness of honeycomb cores. Sometimes a roller is used in
place of the anvil, with equivalent results.
M 79426 F
-- --- - -- --- -

_. ~ - -_
MTL-HDBK-23A CHG N O T I C E 3 E 9999970 0148175 T55 W
F i g u r e 14-7.- - R e s i n - i m p r e g n a t e d g l a s s - f a b r i c h o n e y c o m b showing fuzzy s u r -

f a c e s c a u s e d by bandsa\v cutting.
M 110 455
____ _- ---
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.
MIL-HDBK-23A CHG N O T I C E 3 %'i99970 0348376 9 9 3
c
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Figure 14-8. --Exhaust hose connected to the holes in the guide fence a s a
precautionary measure to remove fine resin and glass dust.
M 100 538

ACffOSS R/000N (Wl D/ffC/ON
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
c
F i g u r e 14-9. --Typical joints between g l a s s - f a b r i c honeycomb c o r e segments;

A, interlocked j o i n t s , overlapped and c o m p r e s s e d ; B I butt joints; C, open
butt joints (limited by specification, usually not o v e r 1 / 2 c e l l in width).
M 111 085
-------- -

-XTRU BAR O f SPECIAL WAX
Figure 14-10. --Extruded bar of specially prepared wax formulation wrapped

with g l a s s fabric, to be u s e d in the l o s t wax p r o c e s s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
M 111 066
--
---------
~

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Figure 14- 11. --Section of typical curved plastic sandwich part made by the
lost wax proces s .
M 100 542

I-
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F i g u r e 14-12. - - A p p e a r a n c e of w a t e r f i l m on a m e t a l s u r f a c e that i s f r e e f r o m
g r e a s e (left) and on a m e t a l s u r f a c e that has not been d e g r e a s e d ( r i g h t ) .
Note t h e continuous w a t e r f i l m on t h e c l e a n e d s u r f a c e (left) and t h e n e a r l y
c o m p l e t e a b s e n c e of a w a t e r f i l m on the g r e a s y s u r f a c e ( r i g h t ) .
M 79538 F

I-
2-PLY GLASS - OTH

FACfNGS
CURED FOAM
GLASS - a o r u
SPA RATORS
A
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Figure 14-13. --Two examples of "multi-core sandwich" for use in specialized

applications.
M 111 067

_ - ~
NII-HDBK-23A CHG N O T I C E 3 W 9999970 OI148182 195 =
M
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MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L 4 L 3 021 m
F i g u r e 14-15. - - T y p i c a l m o l d of thin s h e e t m e t a l s u p p o r t e d by s t e e l f r a m e -
w o r k s u i t a b l e f o r fluid p r e s s u r e molding of a i r c r a f t sandwich i n an auto-
clave.
M 79431 F
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-__ -___ ._ - -~
MIL-HDBK-23A CHG N O T I C E 3 9999970 O L 4 L 8 4 Tb8
Figure 1 4 - 1 6 . --Schematic diagram showing fluid-pressure assembly jig

containing part of a sandwich wing. The jigs hold the component parts
when they are being bonded together into final form.
M 110 983
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CLAMP
tLAME
FLATTENED CUTOUT
FUSION WELD
SOLDER JOINT
OPENING TO PAD
COPPER
G
c
OIL-FILLED METAL BLADDER
Y-
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L-~ANDWICH
PANEL
SUPPORTIM EDGE

Figure 14-17. --Steps in fabricating the oil-filled metal bladder a s shown

in E.
M 111 086

MIL-HDBK-23A CHG N O T I C E 3 9979970 0148LBb 830
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
L OCATION PINS fLASH
MAL MOLD
MOL DED FAG/NGS
FOAMED CORE
Figui-e 14-18. - - D i a g r a m m a t i c s k e t c h of a h e a t e d m o l d f o r u s e with p o u r e d

cores.
M 79678 F

-- _ _ _ _ _ _ _ ~ _ _ _
= 9999970 OL4L7
~
MIL-HDBK-23A CHG N O T I C E 3 777
STOP
BENDING FOffM
F i g u r e 1 4 - 1 9 . - - C o r e b e i n g f o r m e d by m e a n s of a t e n s i o n s h e e t .
M 79679 F
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A C H G N O T I C E 3 = 9999970 OL48L88 603 =
R E I MORCEMEN T
DENSIFIED CORE'
HIGH -S TRENGTH INSER T / EDGE CELLS FILLED'
I I I l. I I I I I I I I l I \c
ME TAL CHANNEL FACINGS FORMED
HIGH-S TRENG TH INSERT\

111111. I
I
CRUSHED AND BONDED
REIN FORCE MEN^

HIGH-S TRENG TH INSERT,
FORMED RING"
SOLID LAMINATE\ TAPERED FACINGS ,\

Y I
Figure 14-20. --Edge treatments.
M 133 232
-..__
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__ - ~ __ ~ -
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0148189 5 4 T
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C METAL XRUS/ON
Figure 14-2 1 . --High-strength i n s e r t s installed during fabrication.
M 113 445

+OR MATERIAL I
A
F i g u r e 1 4 - 2 2 , - - C o r e d e n s i f i c a t i o n by i n s e r t s and c o m p r e s s i o n .
M 110 939
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___ -- -
[ I L - H D B K - ~ ~ A CHG N O T I C E 3 9999970 0 1 4 8 1 9 1 I T 8
B \EXTRffAL BUTT PLAT
Figure 1 4 - 2 3 . - - J o i n t s i n s a n d w i c h f a c i n g s .
M 113 246
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-- ~-~ -
MIL-HDBK-23A C H G N O T I C E 3 m 7777770 O L 4 L 7 2 034 m
I I
Figure 14-24. --Attachment fittings for metal-faced parts.
M 133 231:
-~
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

___- _--
--_
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0148193 T70
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 14-25. - - T - s e c t i o n bonded t o one f a c i n g of a n a l u m i n u m - f a c e d
sandwich.
M 1 1 3 444

___----
NIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 O L ~ B L 9 4 907
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I-
_____-- -- -___.
MIL-HDBK-23A CHG N O T I C E 3 9999970 OL48L9.5 8 4 3
MIL-HDBK-23A
3 0 Dec 1968
CHAPTER 15
INSPECTION AND TEST METHODS
15.1 INSPECTION O F RAW MATERIALS
Once f a b r i c a t e d , it is exceedingly difficult to d e t e r m i n e the quality of

sandwich construction p a r t s . Carefully controlled s y s t e m a t i c inspection of
r a w m a t e r i a l s m u s t be m a d e i n a c c o r d a n c e with rigid m a t e r i a l s s p e c i f i c a -
t i o n s , and the fabrication m u s t be controlled by s t r i c t a d h e r e n c e to rigid
p r o c e s s specifications
Oftentimes the only way of determining conformance to these p r o c e s s

specifications i s through u s e of nondestructive inspection methods. Nonde-
s t r u c t i v e t e s t s a r e an e s s e n t i a l component of production p r o c e s s e s a s well
a s end product inspection. If n e c e s s a r y they c a n b e applied to all p r o c e s s e s ,
components, and a s s e m b l i e s . Most nondestructive indications a r e qualita-
t i v e , not quantitative, and t h e i r i n t e r p r e t a t i o n involves judgment b a s e d on
considerable experience. The relations between discontinuities and the
p e r f o r m a n c e capabilities of m a t e r i a l s and s y s t e m s a r e c r i t i c a l l y dependent
upon the intended s e r v i c e conditions and operating environments. The s i g -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
nificance of t h e s e indications should be initially v e r i f i e d by d e s t r u c t i v e
m e a n s to a s s i s t in l a t e r evaluation of s i m i l a r indications.
- Although a detailed inspection p r o c e d u r e f o r a l l m a t e r i a l s is beyond the
scope of this m a n u a l , a brief d i s c u s s i o n of the inspection methods employed
on s o m e of the key m a t e r i a l s i s p r e s e n t e d f o r guidance.
I
15-1

- - -~~
= 9999970 O L 4 8 L 9 6
~ -~
MIL-HDBK-23A C H G N O T I C E 3 78T
15.1.1 Cores
Specifications n o r m a l l y designate acceptable density r a n g e s and m i n i m u m

s t r e n g t h p r o p e r t i e s f o r c o r e m a t e r i a l s . The acceptance of m a t e r i a l f o r u s e
t h e r e f o r e depends on c a r e f u l inspection f o r weight and s t r e n g t h consistency.
N a t u r a l c o r e m a t e r i a l s , s u c h a s b a l s a and mahogany, v a r y o v e r a urider
weight range than synthetic c o r e m a t e r i a l s making inspection f o r density
conformance of p r i m e consideration. T e n s i l e , c o m p r e s s i v e , o r o t h e r t e s t s ,
as mentioned in s e c t i o n 15.5. 1 a r e s o m e t i m e s m a d e a s p a r t of the i n s p e c -
tion. T h e i r purpose is e i t h e r to i n s u r e p r o p e r s t r e n g t h r e q u i r e m e n t s o r as
a check on o t h e r p r o p e r t i e s , s u c h as the p r o p e r c u r e of the r e s i n in a r e s i n -
, i m p r e g n a t e d g l a s s f a b r i c o r paper honeycomb c o r e . S o m e of the common
c h a r a c t e r i s t i c s of typical c o r e m a t e r i a l s that r e q u i r e investigation by
inspection a r e p r e s e n t e d in table 15 - 1.
15. 1.2 Facings
M a t e r i a l s employed f o r facings, s u c h as v a r i o u s m e t a l alloys and g l a s s -

f a b r i c - r e i n f o r c e d p l a s t i c , p r e s e n t no unusual inspection p r o b l e m s . Metals
must n o r m a l l y conform to applicable m i l i t a r y specifications and m u s t be
f r e e f r o m contamination, c o r r o s i o n , and w r i n k l e s . Before impregnation
g l a s s f a b r i c m u s t b e clean, p r o p e r l y t r e a t e d , and of a definite and uniform --
weave pattern.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
15. 1 . 3 Adhesives and R e s i n s
Adhesives m u s t f i r s t be evaluated f o r t h e i r suitability and p e r f o r m a n c e

i n the type of application f o r which t h e i r u s e i s intended. S o m e s p e c i f i c a -
tions r e q u i r e t h a t bond t e s t s b e m a d e a t specific i n t e r v a l s to d e t e r m i n e that
t h e r e has not been any d e t e r i o r a t i o n of the adhesive. Once a p a r t i c u l a r
..
adhesive has, been s e l e c t e d , inspection m u s t be m a d e to d e t e r m i n e that the
v a r i o u s batches as received a r e the s a m e quality a s the original s a m p l e s ,
and that the adhesives a r e not u s e d when the quality of t h e i r p e r f o r m a n c e
has been reduced by overaging o r i m p r o p e r s t o r a g e . T e s t s of bond s t r e n g t h
have been widely u s e d as a m e a n s of originally selecting the adhesive, d e t e r -
mining the conditions under which the adhesive can be u s e d , and a s a m e a n s
of inspecting the uniformity of the adhesive. Other t e s t s , such a s physical
a p p e a r a n c e , pH, v i s c o s i t y , specific gravity, and s o l i d s content, have a l s o
been u s e d to aid in inspecting the uniformity and s t o r a g e c h a r a c t e r i s t i c s of
adhesives.
Inspection of p a r t s f o r s i z e , p r i o r to bonding, i s e x t r e m e l y i m p o r t a n t in
preventing voids in the finished product. T o l e r a n c e s on bonding fixtures
are equally i m p o r t a n t f o r the s a m e r e a s o n .
15-2

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 7 7 0 O L 4 L 7 bLb
15. 1.3. 1 Adhesive Bond Strength T e s t s
Sandwich f a b r i c a t o r s , i n evaluating and controlling the quality of a d h e s i v e s ,

u s e the t e s t methods outlined i n s e c t i o n 15. 5.
In evaluating adhesives f o r t h e i r p r o c e s s e s , f a b r i c a t o r s m a y u s e s e v e r a l
types of s p e c i m e n s to obtain p r e l i m i n a r y information. Such information m a y
c o n c e r n t h e s t r e n g t h of the adhesive in joints of the m a t e r i a l of the type to
b e bonded; the allowable bonding conditions u n d e r which the adhesive can b e
u s e d , the p e r f o r m a n c e of the adhesive joints when subjected to conditions
simulating actual s e r v i c e , s u c h a s e x p o s u r e s a t high and low t e m p e r a t u r e s
and humidities, soaking i n v a r i o u s fluids, and when subjected to fatigue and
long -time loading.
Bond s t r e n g t h t e s t s to check the quality of the v a r i o u s b a t c h e s of adhesive

o r the quality of adhesive a f t e r s t o r a g e a r e usually m a d e with a lap-joint
s p e c i m e n . T h e s e t e s t s a r e often m a d e at r o o m t e m p e r a t u r e s , but s o m e
f a b r i c a t o r s believe that t e s t s a t low o r at elevated t e m p e r a t u r e s a r e m o r e
s e n s i t i v e in indicating d e t e r i o r a t i o n in the quality of the adhesive.
When adhesives a r e intended p r i m a r i l y f o r bonding sandwich constructions,

t h e s e adhesives should be accepted on the b a s i s of specified acceptance t e s t s .
15. 1 . 3 . 2 Other Adhesive Inspection T e s t s
In inspecting adhesives to c o n t r o l the quality of the m a t e r i a l s being u s e d

in the fabrication of sandwich construction, the adhesives should f i r s t be
examined to s e e that the color and uniformity of m i x a r e the s a m e a s o b s e r v e d
in previously acceptable batches of the adhesive. Most f a b r i c a t o r s then u s e
- s o m e additional t e s t s , s u c h a s v i s c o s i t y , pH, specific g r a v i t y , o r solids
content, to e s t a b l i s h f u r t h e r that the batch of adhesive under t e s t i s of the
s a m e formulation a s batches of t h e adhesive previously u s e d and accepted.
e
A s t h e s e quality-control t e s t s a r e m e r e l y a c o m p a r i s o n of the p r o p e r t i e s of
the s a m p l e u n d e r t e s t with those p r o p e r t i e s previously obtained o n acceptable
s a m p l e s of the adhesive, any method of determining v i s c o s i t y , pH, specific
g r a v i t y , o r solids content that gives reproducible r e s u l t s will prove s a t i s -
f a c t o r y . When any of the foregoing t e s t s indicate that the p r o p e r t i e s of the
adhesive a r e not the s a m e a s those obtained with other s a m p l e s of this adhe-
s i v e , rejection is usually dependent on whether o r not the s a m p l e gives s a t i s -
f a c t o r y r e s u l t s i n joint s t r e n g t h t e s t s .
15-3
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
With c e r t a i n f i l m - t y p e a d h e s i v e s , flow t e s t s a r e m a d e to indicate if
t h e r e has b e e n any reduction in t h i s p r o p e r t y of the adhesive film during
s t o r a g e . A s p e c i f i e d a r e a of t h e f i l m is c u r e d u n d e r specified p r e s s u r e -
t e m p e r a t u r e - t i m e conditions, and t h e r a t i o of t h e final a r e a of the film t o
its o r i g i n a l a r e a is u s e d to indicate the flow p r o p e r t y of t h e adhesive f i l m .
15.2 INSPECTION O F COMPLETED PARTS
Sandwich p a r t s a r e i n s p e c t e d f o r conformance to d i m e n s i o n , weight,

configuration, u n i f o r m i t y , and s t r e n g t h r e q u i r e m e n t s of the applicable
s p e c i f i c a t i o n . T h e r e l a t i v e i m p o r t a n c e and t o l e r a n c e s allowable f o r e a c h
c h a r a c t e r i s t i c depend upon the application. R a d a r -antenna housings r e q u i r e
panels of u n i f o r m and e x a c t t h i c k n e s s , while s t r u c t u r a l panels r e q u i r e
p r i m a r i l y , c e r t i f i c a t i o n of adequate bond s t r e n g t h . S e c o n d a r y s t r u c t u r a l
p a r t s a r e l e s s c r i t i c a l , but m u s t be of p r o p e r s i z e and shape.
R a d o m e s , a f t e r v i s u a l inspection f o r conformance to dimensional r e q u i r e -

m e n t s , a r e often i n s p e c t e d f o r e l e c t r i c a l t r a n s m i s s i o n efficiency and p o s s i -
b l e d i s t o r t i o n of s i g n a l , by a scanning a p p a r a t u s that s i m u l a t e s conditions in
actual u s e .
S t r u c t u r a l p a r t s m u s t be c r i t i c a l l y inspected f o r a r e a s of questionable
bond between .facings and c o r e . A r e a s having no bond a r e usually readily
d e t e c t a b l e by s e v e r a l of t h e common inspection m e t h o d s , but a r e a s having
m e r e l y s u b n o r m a l bond s t r e n g t h a r e exceedingly difficult to locate by i n s p e c -
tion o r n o n d e s t r u c t i v e t e s t m e t h o d s .
Many n o n d e s t r u c t i v e t e s t methods that m a y b e useful in sandlvich i n s p e c -

tion a r e outlined i n ( r e f . 15-7).
T e s t i n g of production s a m p l e s o r t e s t coupons of v a r i o u s p a r t s t o d e s t r u c -
t i o n c a n b e u s e f u l in providing i n f o r m a t i o n on manufacturing techniques and
c o n s i s t e n c y , p r o c e s s c o n t r o l , and s t r u c t u r a l i n t e g r i t y .
1 5 . 2 . 1 Visual InsDection
V i s u a l examination m a d e i m m e d i a t e l y a f t e r a sandwich panel h a s been

r e m o v e d f r o m the p r e s s o r b a g , w h e r e i t w a s c u r e d with h e a t , often r e v e a l s
unbonded a r e a s as b l i s t e r s . T h e s e b l i s t e r s r e m a i n extended f o r a s h o r t
p e r i o d only, o r until t h e d r o p i n panel t e m p e r a t u r e r e d u c e s the i n t e r n a l
p r e s s u r e of the panel. During t h i s s h o r t i n t e r v a l in which t h e b l i s t e r s a r e
v i s i b l e , they m a y b e outlined with a n a p p r o v e d m a r k i n g pen f o r future l o c a -
tion and p o s s i b l e r e p a i r .
15-4 __
-.
-=-_ -----.__
--------

L
c
Visual inspection methods a p p e a r to have only limited u s e f u l n e s s . If a
p a r t h a s b l i s t e r s upon r e m o v a l f r o m the p r e s s o r bag, t h e p r e s e n c e of defec-
tive a r e a s is d e m o n s t r a t e d and the p a r t can b e r e j e c t e d o r m a r k e d f o r s a l -
vage immediately. If no b l i s t e r s a r e v i s i b l e , however, the absence of defec-
tive a r e a s is not proved and the p a r t m u s t be subjected to f u r t h e r t e s t s by a
m o r e dependable method. G l a s s - f a b r i c facings, p a r t i c u l a r l y void-free l a m -
i n a t e s , p e r m i t inspection of the c o r e and s o m e t i m e s aid i n detecting poor
bonds.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
T h e u s e of lights h a s been t r i e d f o r determining faulty a r e a s of b l i s t e r s

in v a r i o u s types of sandwich construction, but mainly in panels with g l a s s -
f a b r i c facings. By varying the a r r a n g e m e n t and angle of lighting s o m e b l i s -
t e r e d a r e a s can b e d e t e c t e d , but not with any d e g r e e of reliability. P o o r l y
bonded areas cannot be detected by m e a n s of lights.
15.2.2 Tapping
Tapping is one of the s i m p l e s t and m o s t effective methods in u s e f o r

t e s t i n g f o r voids in the adhesive bond between the facings and the c o r e of a
sandwich p a r t . The only equipment n e c e s s a r y f o r this t e s t is a s m a l l m e t a l
piece such as a coin o r a small, light h a m m e r .
During inspection by tapping, p a r t s should be f r e e l y supported, a s on

t h r e e padded points, to eliminate sound i n t e r f e r e n c e f r o m the support. A
well-bonded a r e a will produce a c l e a r tone, while a n unbonded a r e a usually
produces a lower tone o r a dull thud.
T h i s method h a s been found to b e reasonably s a t i s f a c t o r y f o r detecting

areas w h e r e the facings of the sandwich a r e not f i r m l y attached to the c o r e .
"
It h a s been found, however, t h a t if t h e r e i s i n t i m a t e contact between t h e
facing and the c o r e , no difference in tone quality can be detected between
t h e s e a r e a s and those t h a t a r e w e l l bonded. P o o r l y bonded a r e a s , t h e r e f o r e ,
cannot be differentiated f r o m well-bonded a r e a s by m e a n s of tapping. T e s t s
have shown t h a t v e r y light tapping is m o r e s e l e c t i v e than a r e heavy blows.
Considerable e x p e r i e n c e is r e q u i r e d to locate defective a r e a s consistently,
b e c a u s e p a r t s of different construction give off different tones and the tones
on a single p a r t v a r y with the position on the p a r t . Variation in tone is
e s p e c i a l l y noticeable within a few inches of the edge.

= 9799970
I- MIL-HDBK-23A
1 5 . 2 . 3 S p u r Wheel
CHG N O T I C E 3 0348200 T 3 0 W
A refinement on the tapping h a m m e r i s the u s e of a ' ' s p u r wheel, ' I which

is similar to the d r e s s m a k e r ' s t r a n s f e r wheel. In u s e the wheel is r u n at a
uniform r a t e a c r o s s the sandwich p a r t and the o p e r a t o r l i s t e n s f o r a change
i n tone. The t e e t h on the wheel should be a c c u r a t e l y s p a c e d s o t h a t the
wheel itself does not produce a v a r i a t i o n in tone. The s p u r wheel i s s o m e -
t i m e s connected to a sound-amplifying s y s t e m to m a k e its use m o r e p r a c t i c a l
w h e r e relatively high background noise i s prevalent.
I 15.2.4 U l t r a s o n i c Inspection
M e t a l p r o d u c t s , s u c h as s t e e l c a s t i n g s , f o r g i n g s , and s h e e t s t o c k , a r e
s o m e t i m e s inspected by the u s e of u l t r a s o n i c v i b r a t i o n s . Hidden flaws,
voids, and o t h e r defects can usually b e located by t h e i r attenuating effect
upon high-frequency vibrations. S e v e r a l u l t r a s o n i c i n s t r u m e n t s which a r e
u s e f u l i n nondestructive testing of sandwich a r e d e s c r i b e d ( r e f s . 15-3, 1 5 - 4 ,
15-5, 15-9, 1 5 - 1 0 , 15-11, 15-15, 15-17, 15-21, 15-22, and 15-30).
15.2.5 Radiographic Inspection

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
_.
F o r m e t a l sandwiches, b r a z e d sandwich in p a r t i c u l a r , i t i s r e p o r t e d
t h a t radiographic inspection offers the m o s t thorough and dependable method
of nondestructive inspecting f o r i n t e r n a l quality. X - r a y will r e v e a l unbrazed
a r e a s , c o r e d e f e c t s , evidence of contamination, and m i s m a t c h e d p a r t s .
X - r a y techniques have a l s o been found valuable for detecting the p r e s e n c e
of m o i s t u r e i n m e t a l sandwiches a f t e r e x p o s u r e . O t h e r defects that can be
located by X - r a y a r e i n c o r r e c t c o r e ribbon d i r e c t i o n , deformed c e l l p a t t e r n
o r incomp.letely expanded c o r e , mislocation o r shifting of c o r e b l o c k s , and
r u p t u r e d bonds between the honeycomb ribbons ( r e f . 15-30). S t e r e o r a d i o -
graphy c a n be employed f o r determining depth of fillets of adhesive o r
braze.
15.2.6 Vibrator - Amplifier Inspection
A nondestructive method of testing m e t a l - t o - m e t a l bonds o p e r a t e s by

introducing a controlled vibration f r o m a "door-bell type'' b u z z e r a t a
localized point d i r e c t l y underneath a s m a l l r o l l e r . A s e n s i n g unit c o n s i s t -
ing of a phonograph "pick-up, " an a m p l i f i e r , and earphones a r e u s e d to
d e t e c t the vibration by placing the pick-up in contact with the bonded
as s e m b ly .
15-6

~ _ _ -- - _ _ _
flIL-HDBK-23A CHG N O T I C E 3 W 9 9 9 9 9 7 0 OLL18201 977
The o p e r a t o r r o l l s the v i b r a t o r o v e r the bond to b e t e s t e d , and l i s t e n s

through e a r p h o n e s f o r a change i n tone as detected by the s e n s i n g unit. A
changcx in tone i n d i c a t e s a d i s c r e p a n c y i n the bond at the point of contact
beneath v i b r a t o r r o l l e r . As defective a r e a s a r e found, they c a n be outlined,
T h e a p p a r a t u s w o r k s w e l l on i r r e g u l a r o r slightly c o r r o d e d s u r f a c e s , i n
production l i n e s , and in a r e a s w h e r e background noise is p r e v a l e n t . T h i s
a p p a r a t u s ,:-however, will only indicate voids, and does not indicate any v a r i -
ation in bond quality that m a y e x i s t .
15.2.7 T h e r m o g r a p h i c Inspection
Disturbancc of cxpccted uniformly d i s t r i b u t e d t h e r m a l conductivity of

sandw.ich panels can be indicative of unbonded a r e a s o r inclusions. Detec-
tion of t h e s e a r r a s is possible by u s e of t h e r m o c o u p l e r e a d i n g s , i n f r a r e d
s e n s i n g photographic o r t e l e v i s i o n c a m e r a s , o r c o l o r changes in liquid c r y s -
tal coatings as uniformly d i s t r i b u t e d heating i s applied to the opposite s a n d -
wich facing ( r e f s . 15-6, 15-8, 15-20, and 15-28). I n v e r s e l y , t h e f r o s t
pattclrn i m m e d i a t e l y f o r m e d when a cooled sand\vich panel i s brought into a
w a r m , m o i s t a t m o s p h e r e m a y a l s o show unbonded a r e a s .
15.3 P R O O F LOADING DEVICES
1 5 . 3 . 1 E x p o s u r c to Vacuum
The f o r c e e x e r t e d by vacuum-induced air p r e s s u r e in the c o r e m a y be

u s e d t o apply a m o d c r a t e load on the bond between facings and c o r e in s a n d -
w.ich p a r t s , providcd t h e facing a n d the c o r e m a t e r i a l s a r e r e l a t i v e l y
i m p e r v i o u s to a i r . I n t e r n a l p r e s s u r e can be c a u s e d by placing panels i n a
vacuum in an autoclave o r vacuum box. O b s e r v a t i o n s a r e m a d e through
windows in t h e autoclave. The magnitude of this f o r c e is dependent e n t i r e l y
upon t h e r a t e of air flow through t h e facings and c o r e of t h e p a r t , but u n d e r
i d e a l conditions cannot exceed a t m o s p h e r i c p r e s s u r e , o r about 14 pounds
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
p e r s q u a r e inch.
T e s t s m a d e by t h i s method on a l u m i n u m - f a c e d p a r t s indicated that a r e a s

having a poor bond could not be d e t e c t e d , and a r e a s having no bond w e r e dif-.
ficult to l o c a t e u n l e s s they w e r e l a r g e o r the facings w e r e v e r y thin. Defects
of this type c a n be located m o r e e a s i l y and with g r e a t e r d e g r e e of a c c u r a c y
by tapping; t h e r e f o r e , t e s t i n g by vacuum a p p e a r s to have little value.
15-7

______
= 7777770
-~ __.
flIL-HDBK-23A CHG N O T I C E 3 0148202 803
P a n e l s c a n b e t e s t e d at h i g h e r i n t e r n a l p r e s s u r e s i f t h e i r edges a r e
s e a l e d and p r e s s u r e is supplied by air pump.
S e n s i t i v e detection of unbonded o r weakly bonded a r e a s c a n be aided by

application of b r i t t l e l a c q u e r o r b i - r e f r i g e n t photoelastic coatings. T h e
coatings a r e o b s e r v e d by o r d i n a r y light o r p o l a r i z e d light as the i n t e r n a l
p r e s s u r e is i n c r e a s e d . Unbonded a r e a s a p p e a r at f a i r l y low p r e s s u r e s even
though f a i r l y heavy facings m a y b e u s e d (ref. 15-29).
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
1 5 . 3 . 2 Vacuum-Induced Concentrated Load

Tester
T h e t e s t e r c o n s i s t s of a dish-shaped c a s t i n g , a p p r o x i m a t e l y 10 inches in
d i a m e t e r , with a r u b b e r g a s k e t around the outside r i m to f o r m a p r e s s u r e
s e a l between the t e s t e r and the sandwich panel. A c e n t r a l r u b b e r - c o v e r e d
s t e e l foot is p r e s s e d a g a i n s t the panel as the d i s h - s h a p e d cavity is evacuated.
Foot s i z e s of different d i a m e t e r s a r e supplied s o that v a r i o u s r a t i o s of c o r e
c o m p r e s s i o n to c o r e s h e a r s t r e s s c a n be applied. A vacuum gage is attached
t o t h e c a s t i n g t o m e a s u r e t h e applied load.
In u s e , t h e t e s t e r is o p e r a t e d by placing it on a sandwich panel, adjusting

the positions of the foot until t h e panel c o n t a c t s both t h e foot and the r u b b e r _- -
g a s k e t , and drawing a p a r t i a l vacuum on t h e c a s t i n g until f a i l u r e o c c u r s o r

until s o m e d e s i r e d proof load, d e t e r m i n e d by t h e setting on t h e poppet v a l v e ,
is r e a c h e d .
The t e s t e r a p p e a r s to be a f a i r l y reliable detection device on flat s a n d -

wich c o n s t r u c t i o n s having aluminum honeycomb, g l a s s - f a b r i c honeycomb,
o r b a l s a c o r e s . P o o r bonds between facings and c o r e in flat panels having
c o r e s of aluminum-foil honeycomb, g l a s s - f a b r i c honeycomb, o r b a l s a can
be d e t e c t e d by p r o p e r u s e of the t e s t e r .
T h e Sensitivity of the t e s t e r is about equal to the sensitivity of f l e x u r e

t e s t s f o r d e t e r m i n i n g poor bonds, but n e i t h e r is as s e n s i t i v e as t h e f l a t w i s e
tension test.
15.3.3. Multiple P r o o f L o a d e r
E s s e n t i a l l y , a multiple proof l o a d e r is a r e p l i c a of one s i d e of a c u r v e d

o r flat panel. The device is b e s t adapted to u s e in t e s t i n g flat o r s i n g l e -
c u r v e d sandwich c o n s t r u c t i o n s .
15-8

__ ~ -~-___-__ ~-__ ~-
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 0348203 7 4 T m
U s e of the multiple proof l o a d e r will c a u s e f a i l u r e of poor bonds in a

panel being t e s t e d . Its controlled u s e on panels p r o p e r l y bonded will not
c a u s e f a i l u r e of the bonds.
T h e sensitivity of the multiple proof l o a d e r in differentiating between

poorly bonded a r e a s and well-bonded a r e a s was found to be b e t t e r than a
s h o r t e d g e - c o m p r e s s i o n t e s t , equal to that of the flexure t e s t , and lclss than
that of either a tension o r p e e l t e s t .
The proof l o a d e r b a s e i s f a b r i c a t e d of r e s i n - i m p r e g n a t e d g l a s s f a b r i c
and is r i g i d enough t o r e t a i n i t s shape when the b a s e i s subjected to the
s t r e s s e s of the vacuum t e s t . (Other rigid m a t e r i a l s c a n a l s o be u s e d f o r
the b a s e . ) The mold f r o m which the sandwich panels a r e m a d e is a l s o u s e d
to f o r m the proof l o a d e r b a s e , figure 1 5 - 1 . F o r e x a m p l e , a multiple proof
l o a d e r b a s e u s e d f o r testing wing skins can be f o r m e d f r o m the wing skin
molds.
After the wing skin is f a b r i c a t e d and is t o be t e s t e d , i t i s r e s t e d on

contact buttons on the concave side of the proof l o a d e r (for curved p a n e l s ) .
T h e buttons a r e placed in c h e c k e r b o a r d fashion to produce the d e s i r e d proof
load. When p r o p e r l y positioned, the wing skin panel will b e situated u.ithin
a r u b b e r g a s k e t , which is located along the edge of the proof l o a d e r b a s e on
t h e concave s i d e . A vacuum gage is mounted on the convex s i d e of the
proof l o a d e r b a s e .
A p r e d e t e r m i n e d p a r t i a l vacuum i s applied to the e n c l o s u r e between the

vacuum b a s e and the sandwich panel. If a faulty bond is p r e s e n t between
facing and c o r e on e i t h e r side of the c o r e , a s h a r p audible c r a c k will be
h e a r d b e f o r e the p r e d e t e r m i n e d vacuum i s reached and the p a r t i s c l a s s e d
as not acceptable.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
15.4 SPECIFICATIONS
None of the inspection o r nondestructive t e s t methods in u s e a t p r e s e n t

a p p e a r to b e an e n t i r e l y dependable m e a n s of inspecting sandwich p a r t s f o r
quality of joints. Also, any s u c h inspection method could a t b e s t detect
poor panels a f t e r f a b r i c a t i o n , and cannot be c o n s i d e r e d a r e p l a c e m e n t f o r
quality c o n t r o l during p r o c e s s i n g . T h e r e f o r e , a d h e r e n c e t o adequate m a t e -
r i a l and p r o c e s s specifications, supplemented by sufficient d e s t r u c t i v e
tests, i s n e c e s s a r y to i n s u r e u n i f o r m high-quality joints i n sandwich panels.
15-9

. --___--~
NIL-HDBK-23A CHG N O T I C E 3 E 9999970 0348204 686 =

L 15.5 TEST METHODS
t
E x p e r i e n c e in testing sandwich constructions h a s been sufficiently

extensive to e s t a b l i s h s o m e p r o c e d u r e s . They a r e d e s c r i b e d in M i l i t a r y
S t a n d a r d MIL-STD-401 ( r e f s . 15-2 and 15-23).
15.5. 1 T e s t Methods f o r C o r e M a t e r i a l s
C o r e m a t e r i a l s a r e s o m e t i m e s difficult to t e s t because they m a y not

have sufficient rigidity o r h a r d n e s s to support s t r a i n gages o r b e c a u s e they
m a y be available only in thin s h e e t s . A n u m b e r of methods of t e s t have
been devised. They a r e d e s c r i b e d in detail in M i l i t a r y Standard
MIL-STD-401 (15-2 and 15-23).
15. 5 . 2 T e s t Methods f o r Adhesives and

f o r Bonded Joints
Many types of t e s t s p e c i m e n s and d e s t r u c t i v e t e s t methods have been

developed f o r evaluating the quality of adhesive bonds in m e t a l - t o - m e t a l
( r e f . 15-27) and in sandwich construction ( r e f s . 15-24 and 1 5 - 2 5 ) . The _-
r e s u l t s obtained f r o m t h e s e t e s t s a r e usually f o r the purpose of comparing
the quality of adhesive bonding, a s i t is difficult with many of the t e s t s to
apply the values d i r e c t l y to the design of bonded p a r t s .
I 15. 5 . 3 Lap-Joint Metal-to-Metal S h e a r T e s t
A lap-joint s p e c i m e n of two thin s h e e t s of m e t a l overlapped for a s h o r t

distance a t the ends h a s been widely u s e d in the evaluation and control t e s t -
ing of adhesives f o r m e t a l - t o - m e t a l and sandwich bonding. T h i s specimen
and its method of t e s t s a r e d e s c r i b e d in F e d e r a l Specification MMM-A- 1 3 2
( r e f . 15-27) and in ASTM S t a n d a r d D-1002 ( r e f . 15-1).
Clad aluminum alloy ( O . 064 inch) s h e e t s with a n o v e r l a p distance of

O. 5 inch have frequently been u s e d in fabricating this type of specimen.
One-inch-wide s p e c i m e n s a r e then cut f r o m bonded p a n e l s , o r prepunched
s h e e t s m a y b e u s e d to eliminate sawing n e a r the bond line. Other m e t a l s
such a s m a g n e s i u m , s t a i n l e s s s t e e l , and titanium, have a l s o been used in
this type of s p e c i m e n .
15-10
.-*_--_
----------
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HDBK-23A CHG N O T I C E 3 = 9999970 0148205
- ~ _ _ _
512 =
e
When the lap-joint s p e c i m e n is s t r e s s e d by applying a tension load,
bending a l s o o c c u r s within t h e s p e c i m e n , s u c h as shown in f i g u r e 15-2.
T h e r e f o r e , in addition to t h e complicated distribution of s h e a r s t r e s s along
the bond line b e c a u s e of d i f f e r e n c e s in t h e moduli of e l a s t i c i t y of a d h e r e n d
and a d h e s i v e , t h e r e a r e t e a r i n g s t r e s s e s n o r m a l to t h e bond line. T h e d i s -
t r i b u t i o n of t h e s e s h e a r and t e a r i n g s t r e s s e s is dependent on t h e length of
o v e r l a p , modulus of e l a s t i c i t y and thickness of t h e a d h e r e n d , modulus of
e l a s t i c i t y . modulus of r u p t u r e , and t h i c k n e s s of t h e a d h e s i v e ( r e f s . 15-16
and 15-18). E x a m p l e s of r e l a t i o n s h i p s of s h e a r s t r e s s , n o r m a l s t r e s s , and
thc a p p a r e n t a v e r a g e s h e a r s t r e s s value a r e shown in f i g u r e 15-3 a s c o m -
puted ( r e f . 15-18) f o r a d h e s i v e s with low and high e l a s t i c modulus. A s the
a p p a r e n t a v e r a g e s h e a r s t r e n g t h v a l u e s computed f o r the bond a r e a a r e
dependent on the s e v e r a l p r o p e r t i e s of both a d h e r e n d and a d h e s i v e , t h e s e
avcragc s h e a r values c a n be u s e d f o r d i r e c t c o m p a r i s o n s only when identical
t y p c s of s p c c i m e n s a r e u s e d f o r a l l t e s t s .
The v a r i a b i l i t y of bond t e s t s m a d e with lap-joint s p e c i m e n s u n d e r condi-

t i o n s believed to b e identical h a s u s u a l l y been c o n s i d e r e d to b e f a i r l y high.
In a s u r v e y study m a d e ( r e f . 15-12), among f a b r i c a t o r s of bonded j o i n t s ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
thc coefficient of v a r i a t i o n of t h i s type of t e s t w a s found to be 6 to 10 p e r c e n t
in l a b o r a t o r y and adhesive a c c e p t a n c e t e s t s and 10 to 16 p e r c e n t in p r o d u c -
tion c o n t r o l t e s t s .
Thc v a r i a b i l i t y in t h e s e lap-joint bond t e s t s can be a t t r i b u t e d to many

p o s s i b l e c a u s e s s u c h a s v a r i a t i o n s in:
The bonding c h a r a c t e r i s t i c s of m e t a l s h e e t s f u r n i s h e d by
di f f c r ent manu f a c tu r e r s .
The s m o o t h n e s s of t h e edge of t h e s h e e t being bonded. In

clipped m e t a l e d g e s , the o r i e n t a t i o n of the b u r r e d edge is believed
t o influence the failing s t r e n g t h of t h e joint.
. The c o n t a m i n a t e s on t h e s u r f a c c s and the cffectiveness of t h e

prebonding t r e a t m e n t s i n p r e p a r i n g the m e t a l s u r f a c e f o r bonding.
The drying conditions a f t e r prebonding t r e a t m e n t s and b e f o r e

t h e a d h e s i v e i s applied to the s u r f a c e .
The t e m p e r a t u r e , humidity, and o t h e r conditions u n d e r which

t h e a d h e s i v e s a r e applied.
The f o r m u l a t i o n of t h e a d h e s i v e s and changes during aging of

t h e adhesive s a m p l e .
15-11

-~ _ _-
MIL-HDBK-23A CHG N O T I C E 3 9999970 OL4B20b 4 5 7
A bonded panel in the bonding conditions and m e t h o d s , s u c h a s

amount of adhesive applied, p r e c u r e and c u r e conditions, and
uniformity of p r e s s u r e .
The h e a t and vibration that s p e c i m e n s a r e subjected to during

the cutting operation.
The testing technique, including the distance between j a w s ,

alinement of jaws and t e s t s p e c i m e n s , t e m p e r a t u r e c o n t r o l , and
r a t e of loading.
One m u s t allow f o r t h e s e v a r i a b l e s , not only when using lap-joint s p e c i -

m e n s , but a l s o when one applies o t h e r types of t e s t s to the metal-bonding
adhesives.
C a r e f u l p r o c e s s control is n e c e s s a r y to reduce the v a r i a t i o n s indicated

above a s r e q u i r e d by the v a r i o u s m i l i t a r y specifications.
15. 5.4 L a p - J o i n t S h e a r T e s t a t Various

Temperatures .
The lap-joint s h e a r t e s t is frequently u s e d to indicate the p e r f o r m a n c e
of adhesive bonds o v e r a wide t e m p e r a t u r e range. T e s t s a r e m a d e by h e a t -
ing o r cooling the bond line of the s p e c i m e n to the r e q u i r e d t e m p e r a t u r e in
c i r c u l a t i n g - a i r c h a m b e r s , o r by the u s e of t h e r m o s t a t i c a l l y controlled
small cylindrical ovens that will maintain the t e m p e r a t u r e within I 2 " F of
the r e q u i r e d t e m p e r a t u r e . Radiant heat ovens a r e a l s o u s e d in this type of
testing. Thermocouples attached to both f a c e s of the l a p a r e a a r e used to
indicate the t e m p e r a t u r e . When radiant heating is u s e d , the thermocouple
junctions should b e shielded to prevent e r r o r i n reading the t e m p e r a t u r e s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Variations in the r e s u l t s of t h e s e t e s t s m a y be obtained, depending on
the t i m e r e q u i r e d to bring the s p e c i m e n to the r e q u i r e d t e m p e r a t u r e f o r
t e s t i n g . This t i m e m,ay v a r y , depending on t h e h e a t capacity of the t e s t
c h a m b e r and whether the t e s t jaws a r e located within o r outside of the t e s t
chamber.
T h e p r o c e d u r e s as e s t a b l i s h e d in F e d e r a l Specifications s u c h as
MMM-A-132 ( r e f , 15-27) should be followed,
15-12
_I-- --

c
1 5 . 5 . 5 -La$-3oint S h e a r T e s t After Exposure
T h e durability and o v e r a l l p e r f o r m a n c e of metal-bonding adhesives a r e

often evaluated by p r e p a r i n g lap-joint panels with the adhesives and then
subjecting.thes.e panels o r s p e c i m e n s cut f r o m t h e s e panels to v a r i o u s types
of e x p o s u r e s . After e x p o s u r e , t h e s e s p e c i m e n s a r e t e s t e d to f a i l u r e by the
r e g u l a r methods as d e s c r i b e d i n section 15.5.3.
1 5 . 5 . 6 Lap-Joint Specimens i n Fatigue

,
Testing
I'!
Thei-ap-joint t e s t s p e c i m e n (section 15.5.3) c a n a l s o be u s e d to d e t e r -
m i n e the fatigue c h a r a c t e r i s t i c s of the metal-bonding a d h e s i v e s . S t r e s s e s
a r e applied i n cycles varying f r o m the m a x i m u m s e l e c t e d s t r e s s to 10 p e r -
cent of this m a x i m u m s t r e s s .
Curves showing s t r e s s n u m b e r of cycles to f a i l u r e can be established

f o r the adhesive by s t r e s s i n g s p e c i m e n s to f a i l u r e , using selected maximum
s t r e s s e s . A typical s t r e s s n u m b e r of cycles to f a i l u r e c u r v e i s shown in
f i g u r e 15-4.
Fatigue t e s t s can be m a d e o v e r a wide t e m p e r a t u r e range by using ovens

and conditioning c h a m b e r s surrounding the t e c t s p e c i m e n s . Fatigue t e s t s on
l a p joints of aluminum a t low t e m p e r a t u r e s (-67 O F ) , however, have gen-
e r a l l y shown fatigue s t r e n g t h s of the bonds equal to o r g r e a t e r than those
obtained at r o o m t e m p e r a t u r e s , and even urith the s h o r t 3/8-inch o v e r l a p
s p e c i m e n , m e t a l tension f a i l u r e s frequently w e r e noted r a t h e r than adhesive
failures.
1 5 . 5 . 7 Use of Lap-Joint Specimens in

Long-Time Loading
The lap-joint s p e c i m e n (section 15. 5. ) is a l s o u s e d to d e t e r m i n e the

long-time load and c r e e p p r o p e r t i e s of adhesives (ref. 15-27). Applied loads
a r e s e l e c t e d s o t h a t the length of t i m e to f a i l u r e f o r the s p e c i m e n s will range
o v e r the i n t e r v a l f r o m O . 1 to 200 h o u r s . The s t r e s s - t i m e to f a i l u r e curve
can be e s t a b l i s h e d , and the point w h e r e this c u r v e i n t e r c e p t s the ZOO-hour
ordinate is c o n s i d e r e d the long-time load s t r e n g t h . A typical s t r e s s - t i m e
t o r u p t u r e c u r v e is shown in figure 15-5. T e s t s m a y be m a d e o v e r a wide
range of t e m p e r a t u r e s f r o m r o o m t e m p e r a t u r e u p to the m a x i m u m t e m p e r a -
t u r e the adhesive will withstand.
15-13
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ____- --_____-
MIL-HDBK-23A CHG N O T I C E 3 W 9799970 O 1 4 8 2 0 8 2 2 1

I
e M e a s u r e m e n t s a r e a l s o m a d e during the long-time loading to indicate
the deformation of the adhesive film. S c r i b e m a r k s a r e m a d e a c r o s s e a c h
of the two edges of the overlapped a r e a at distances of 1 / 3 2 inch f r o m the
ends of t h e o v e r l a p and a l s o at the c e n t e r of the overlap. The deformation
of e a c h of t h e s e lines is then m e a s u r e d , using a traveling m i c r o s c o p e a f t e r
v a r i o u s i n t e r v a l s of the loading period. A c a m e r a a r r a n g e d with automatic
timing devices can be u s e d f o r obtaining the c r e e p deformations. T e s t
r e s u l t s indicated (ref. 15-19) t h a t the deformation at the ends of the l a p
joint is frequently g r e a t e r than obtained at t h e c e n t e r . The typical load
t i m e - d e f o r m a t i o n c u r v e shown in figure 15-6 p r e s e n t s extensive information
on the c r e e p of adhesive-bonded joints u n d e r constant load.
R E F E R E N C E D DOCUMENTS

Current Strength P r o p e r t i e s of Adhesives in S h e a r by Tension Load-
ing (Metal-to-Metal). ASTM Standard D1002.

Current T e s t Methods f o r S t r u c t u r a l Sandwich Constructions. ASTM
Standards.
(15-3) ANDERSON, R . E .
1957. Non-Destructive Testing of Bonded Metal Sandwich S t r u c t u r e s .
F
A m e r . Soc. T e s t . and M a t e r . Symposium S T P 201.
(15-4) ARNOLD, J.S.

1957. U l t r a s o n i c Technique f o r Non-Destructive Evaluation of
Metal-to-Metal Adhesive Bonds. A m e r . Soc. T e s t . and
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
M a t e r . Symposium S T P 201.
(15-5) ARNOLD, J.S.

1957. Development of Nondestructive T e s t s f o r S t r u c t u r a l Adhesive
I
Bonds. Wright A i r Develop. Center Tech. Rep. 54-23 1,

P a r t 6.
(15-6) AUTOMATION INDUSTRIES, INC.

1967. Nondestructive Evaluation of M a t e r i a l P r o p e r t i e s Through
U s e of a T h e r m a l Inspection S y s t e m . A i r F o r c e M a t e r i a l s
L a b o r a t o r y , AFML-TR - 6 6 - 192. W r i g h t - P a t t e r s o n A F B ,
Ohio o
15-14
----

= 9999970 0148209 168 =
-.__ ~
c
(1 5-7) BALDANZA, NICHOLAS T.

1955. A Review of Nondestructive Testing f o r P l a s t i c s : Methods
and Applications. P l a s t e c R e p o r t 22; P l a s t i c s T e c h n i c a l
Evaluation C e n t e r , Picatinny A r s e n a l , Dover, N. J .
(15-8) BORUCKI, JAMES S.

1962. T h e Advancement of T h e r m a l T e s t Methods in Nondestructive
T e s t i n g of A i r c r a f t and M i s s i l e Components. M e t a l T r e a t i n g
Magazine. (June-July).
(15-9) DICK, P A U L
1965. Nondestructive T e s t Equipment f o r P r e d i c t i n g and P r e v e n t i n g
F a i l u r e . A m e r . Soc. Mech. Eng. P a p e r 65-MD-26.
(15-10) DIETZ, A . G . H . , BOCHSTRUCK, H . N . , EPSTEIN, G.

1952. Nondestructive Determination of Mechanical P r o p e r t i e s and
D e t e r i o r a t i o n of Adhesives. A m e r . Soc. T e s t . and M a t e r .
Symposium S T P 138.
(15-11) EBERHARDT, C.A.

1962. M a t e r i a l - B r a z e d Honeycomb P a n e l R e p a i r s , Sonic Vibration
T e s t . A r m e d S e r v i c e s Tech. Info. Agency A c c e s s i o n No.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
AD-283028,
(15-12) EICKNER, H. W.
1957. G e n e r a l S u r v e y of Data on the Reliability of Metal-Bonding
Adhesive P r o c e s s e s . F o r e s t P r o d . Lab. R e p . 1862.
(15-13) EICKNER, H. W., and WERREN, F R E D

1954. C o m p a r i s o n s of T e s t Methods of Evaluating Adhesives f o r
Bonding M e t a l F a c i n g s t o M e t a l Honeycomb C o r e s . Wright
A i r . Develop. C e n t e r Tech. Rep. 54-138.
(15-14) EICKNER, H . W . , and WERREN, F R E D

1956. Development and Evaluation of Climbing Peel Method f o r
T e s t i n g Adhesive Bonds i n Sandwich and Metal-to-Metal Con-
s t r u c t i o n s . Wright A i r Develop. C e n t e r Tech. Rep. 56-386.
(15-15) FILIPPI, F. J .
1959. Qualitative Analysis of B r a z e d Sandwich. Nondestructive
T e s t i n g , Vol. 17, No. 1.
(15-16) GOLAND, M . , and REISSNER, E.

1944. S t r e s s e s i n Cemented J o i n t s . J o u r n a l of Applied Mechanics,
Vol. 11, No. 1 , P. A-17 through A-27 ( M a r . ) .
15-15
-
--------

- . _ -______ -
IIL-HDBK-23A CHG N O T I C E 3 9999970 O L 4 8 2 L O 9 8 T W
(15-17) HUGHES, E . T . , and BURSTEIN, E . B.

1959. Evaluation of Bond Quality in Honeycomb P a n e l s Using
U l t r a s o n i c S u r f a c e Waves Techniques. Nondestructive T e s t -
ing, Vol. 17, No, 6, p. 373-377. (Reprinted in A i r c r a f t and
M i s s i l e s , Vol. 3 , No. 6 , p. 42-45. 1960).
(15-18) KUENZI, EDWARD W.

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
1963. Determination of Mechanical P r o p e r t i e s of Adhesives f o r

U s e in the Design of Bonded J o i n t s . U.S. F o r e s t S e r v . R e s .
Note F P L - O l l . F o r e s t P r o d . Lab. , Madison, W i s .
(15-19) MERRIMAN, H . R . , and GOPLEN, H . L .

1957. R e s e a r c h on S t r u c t u r a l Adhesive P r o p e r t i e s O v e r a Wide
T e m p e r a t u r e Range. P a r t II. Wright A i r Develop. C e n t e r
v
Tech. Rep. 56-320.
(15-20) SABOURIN, LaMARR

1966. Nondestructive T e s t i n g of Bonded S t r u c t u r e s with Liquid
C r l t a l s . IN P a p e r s f r o m the S t r u c t u a l Adhesive Bonding
C o n f e r e n c e s , p r e s e n t e d M a r c h 15-16, 1966. Manuf. Eng.
L a b . , M a r s h a l l Space Flight C e n . , NASA, Huntsville, Ala.
(15-21) S C H L I E K E L M A " , R . J.
1964. Nondestructive Testing of Adhesive-Bonded M e t a l S t r u c t u r e s .
P a r t 1: T h e o r e t i c a l Considerations. Adhesives Age, Vol. 7 ,
No. 5, p. 30-35 (May).
(15-22) SMITH, DONALD F . , and CAGLE, CHARLES V.

1966. U l t r a s o n i c Testing of Adhesive Bonds Using F o k k e r Bond
T e s t e r . M a t e r i a l s Evaluation. Vol. XXIV, No. 7 , p 362-370
(July) *
(15-23) U . S . ' D E P A R T M E N T O F DEFENSE

Current Sandwich Constructions and C o r e M a t e r i a l s ; G e n e r a l T e s t
Methods. M i l i t a r y S t a n d a r d MIL-STD-40 1.

Current Adhesive Bonded M e t a l A i r c r a f t P a r t s ; P r o c e s s and Inspec-
tion R e q u i r e m e n t s .

Cur rent Metallic S t r u c t u r a l Sandwich Cons t r u c t ion. Milit a r y S pe cif i -
cation MIL-A-25463.
15-16

(15-26) U.S. GENERAL SERVICES ADMINISTRATION
1956. Adhesives; Methods of Testing. F e d e r a l T e s t Method S t a n d a r d
No. 175. F e d e r a l Supply S e r v i c e .
(15-27) U.S. GENERAL SERVICES ADMINISTRATION

Current A d h e s i v e s , H e a t R e s i s t a n t , A i r f r a m e S t r u c t u r a l , Metal-to-
Metal. F e d e r a l Specification MMM-A- 132, D e p a r t m e n t of
Defense, F e d e r a l Supply S e r v i c e .
(15-28) U . S . NAVAL AIR ENGINEERING CENTER

1967. Liquid C r y s t a l s as a Nondestructive Inspection Tool,
.
Feas ibility Study R epo rt NAE C -AM L 2 63 4. -
1966. Inspection of Honeycomb S t r u c t u r e s Using Bi-Refringent

P l a s t i c Coatings. IN P a p e r s ' f r o m t h e S t r u c t u r a l Adhesive
Bonding C o n f e r e n c e s , p r e s e n t e d M a r c h 15-16, 1966. Manuf.
E n g , L a b . , M a r s h a l l S p a c e Flight C e n . , NASA, Huntsville,
Ala.
(15-30) WEIHER, E A R L R .
1956. U l t r a s o n i c v s . Radiographic Inspection of Bonded and B r a z e d
Assemblies, ..
An Evaluation. A m e r i c a n Machinist.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
15-17
--
--
Provided by IHS
1
-- L
MIL-HDBK-23A CHG N O T I C E 3 148212 752
9999970 00148212 m
e
Table 15-1. - - P r i n c i p a l c o r e m a t e r i a l c h a r a c t e r i s t i c s
that r e a u i r e inspection
Core material Characteristics

: (in o r d e r of importance)
1
B a l s a and m a h o g a n y . Density, defects, - slope of
g r a i n , m o i s t u r e content
P a p e r honeycomb C u r e , configuration, bond-

ing, density
Metal honeycomb Bonding, alloy, configura-

tion, p e r f o r a t i o n , density
Glass -fabric honeycomb Configuration, bonding,

r e s i n content, density,
dielectric properties
Foamed-in -place Foaming c h a r a c t e r i s t i c s ,

uniformity of f o a m ,
density
t
1
- C o m m o n defects a r e knots, r o t , w o r m h o l e s , wane,
c h e c k s , and s p l i t s .
-
_- -
_. -- _________-
----
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._ -
c
__ _-
= 9999970 OL48213
-
F i g u r e 15-1. - - T h e mold (right) f r o m which the proof l o a d e r b a s e

( c e n t e r ) and the sandwich t e s t panel (left) w e r e f o r m e d . The b a s e
is shown with the r u b b e r rim g a s k e t , contact buttons, and vacuum
gage connections.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__
~~ ~
I -___--
MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 8 2 3 4 5 2 5
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
2 n lu 062
F i g u r e 1 5 - 2 . - - T y p e of bending that occurs in singlelap-joint s p e c i m e n

when loaded in tension.

-- -
A 2
- I l I I
O O.w ao8 a12 0.16 0.20 0.24 0.28
X IINCHJ
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I SHEAR. STRESS-+'
/ /
y A V E R A G E SHEAR STRESS I
I I I
0.04 0.08 o.I2 azo
B O,16 0.24 0.28
X IINCHJ
M 134 962
Figure 15-3. --Theoretical relationship of shear and normal s t r e s s e s
in l/r?-inch lap-joint specimen of O. 064-inch clad 2024-T3 aluminum,
loaded with 3 0 0 pounds per inch of width; A , when bonded with an
adhesive of low elastic modulus; B , when bonded with an adhesive of
high elastic modulus.
w
. -. .

-- .- - _ .-
MIL-HDBK-23A CHG N O T I C E 3 E 9999970 O L 4 2 L b 3 T W
<
1,
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MIL-HBBK-23A CHG N O T I C E 3 7777970 0148217 234
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- - _-__- ~ _ _ _ _ _ ~ - ._~_- -
MIL-HDBK-23A CHG N O T I C E 3 m 7 9 9 9 9 7 0 OL482LB 1 7 0 m
0.014 I I I I III
I I I I1111 I I111111 I I I I I III I
o.o/.?
I
8 0.008
r'
STRESS OF 3,100 PSI IN ADHESIVE

GLUE LINE THICKNESS 0.0103 INCH
DISTNCE FROM SCRIBE LINE TO JOINT END.'
I- 0.03 IMCH FROM TOP
Y.YYT y
3- 0.0.3 INCH FROM BOTTOM
0.002 . .
I I I I I III I I I11111 I I. I I I I I I I I I I II I I
A 0.1 I
o.020
r
Y
P
e
0.018
0.016
r-
STRESS OF 1,300 P S J IN ADHESIVE
I
GLUE LINE THICKNESS 0.00% INCH
DISTANCE FROM SCRIBE LINE TO JOINT END..'
I- 0.03 INCH FROM TOP
2- CENTER
O. .008
- 3-0.03 INCH FROM BOTTOM
I I1111111 I I I I I1111 I I 1 1 1 1 1
IO IO0 4 70
TIME IHOURSI
.. .._..
. .-I
Figure 15-6. --Typical load time-deformation curve, during creep-

- k p t u r e t e s t for lap-joint specimen bonded with: -
A , adhesive of
high rigidity; B , adhesive of low rigidity. -
--- - - = - E - -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I
--
-_-- ~ _ _ I _ _ ~
MIL-HDBK-23A C H G N O T I C E 3 W 9999970 O l Y Z L 007
MIL-HDBK-23 A
3 0 D r c 1968
CHAPTER 16
R E PAIR
16.1 GENERAL
W i t h the application of sandwich c o n s t r u c t i o n , as Lvith any o t h e r tvpv of

c o n s t r u c t i o n , i t is inevitable t h a t a c e r t a i n amount of damage will o c c u r .
During the manufacturing s t a g e s , where h a z a r d s of dropped tools and equip-
m e n t a r e e n c o u n t e r e d , s e r i o u s d a m a g e to sandw.ich p a r t s m a y be eliminated
by protecting exposed c o r n e r s and by using t e m p o r a r y protectivc- c o v ( r s ,
P r o p e r p r e c a u t i o n s \vil1 m i n i m i z e d a m a g e s ; but when damage does r e s u l t ,
a c c e p t a b l e methods of r e p a i r m u s t be available.
The possibility of combining m a n y m a t e r i a l s in a v a r i e t y of sandu.ich

c o n s t r u c t i o n s p r e c l u d e s the p r e s e n t a t i o n of d e t a i l e d r e p a i r p r o c e d u r e s f o r
all m a t e r i a l combinations. R e p a i r methods that have b r e n used to givc
r e a s o n a b l e r e s u l t s a r e p r e s e n t e d i n the follo\ving s e c t i o n s f o r s o m < -of t h r
typical sandwich combinations. Inclusion of this i n f o r m a t i o n on r e p a i r s
d o e s not provide a u t h o r i z a t i o n f o r any r e p a i r s of defects iii nc*\: p a r t s .
Requirements f o r s u c h r e p a i r s a r e given i n specifications o r c o n t r a c t s .
16.2 PRINCIPLES O F REPAIR
R e p a i r p r o c e d u r e s a r e developed with the objective of cqiialing. a s

n e a r l y as p o s s i b l e , the s t r e n g t h of the o r i g i n a l p a r t with a m i n i m u m of
i n c r e a s e in weight o r change in aerodynamic c h a r a c t e r i s t i c s and e l e c t r i c a l
p r o p e r t i e s w h e r e applicable. T h i s c a n only be accomplished by replacing
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
d a m a g e d m a t e r i a l with identical m a t e r i a l o r a n approved s u b s t i t u t e . In
o r d e r to e l i m i n a t e dangerous s t r e s s c o n c e n t r a t i o n s , a b r u p t changes in
c r o s s - s e c t i o n a l a r e a s m u s t bc avoided lvhenever practicable. by t a p e r i n g
j o i n t s , by making s m a l l patches round o r oval-shaped i n s t e a d of r e c t a n g u l a r ,
and by rounding c o r n e r s of a l l l a r g e r e p a i r s . Smoothness of outside s u r -
faces of high-speed a i r c r a f t i s a n e c e s s i t y f o r p r o p e r p e r f o r m a n c e , and con-
sequently patches t h a t p r o j e c t above the o r g i n a l s u r f a c e m u s t be avoided if
a t all p o s s i b l e . When this is i m p o s s i b l e , the edges m u s t be generously
t a p e r e d t o fair the r e p a i r into the o r i g i n a l contour. Uniformity of thickness
of c o r e and facings is exceedingly i m p o r t a n t in the r e p a i r of the c r i t i c a l
areas i n r a d o m e s . R e p a i r s of punctured facings and f r a c t u r e d c o r e s in
t h e s e a r e a s , t h e r e f o r e , n e c e s s i t a t e r e m o v a l of all the damaged m a t e r i a l ,
followed by its r e p l a c e m e n t with t h e s a m e type of m a t e r i a l and in the s a m e
t h i c k n e s s and r e s i n - g l a s s r a t i o a s the original. -
16-1

- __ __ ~
MIL-HDBK-23A CHG N O T I C E 3 9999970 OLY8220 8 2 9
R e p a i r s r e f e r r e d t o in this Handbook a r e field r e p a i r s , and m a j o r

r e p a i r s a r e not allowed on new p a r t s . E v e n m i n o r r e p a i r s 3n new p a r t s a r e
d i s c o u r a g e d and can only be u s e d in a c c o r d a n c e with the provisions of appli-
cable m i l i t a r y specifications.
Attempts have been m a d e to simplify the r e p a i r techniques p r e s e n t e d in

t h i s Handbook without s a c r i f i c i n g s t r e n g t h of the p a r t . Even s o , it i s r e a l -
ized that p e r s o n n e l with l i t t l e o r no e x p e r i e n c e with the m a t e r i a l s and
techniques involved in making r e p a i r s t o s t r u c t u r a l sandwich p a r t s m a y have
difficulty i n i m m e d i a t e l y i n t e r p r e t i n g the p r o c e d u r e and in making acceptable
r e p a i r s i n the f i r s t attempt. I t is t h e r e f o r e recommended that inexperienced
p e r s o n n e l be c e r t i f i e d on e a c h type of r e p a i r they may be r e q u i r e d to make
i n s e r v i c e a i r c r a f t before they a r e allowed t o r e p a i r actual a i r c r a f t p a r t s
f o r l a t e r s e r v i c e u s e . This c e r t i f i c a t i o n m a y be accomplished in v a r i o u s
w a y s , among which a r e t h e following:
a. R e p a i r s to s i m u l a t e d d a m a g e s i n f l a t sandwich panels of a c o n s t r u c -
tion s i m i l a r t o the p a r t s to be l a t e r r e p a i r e d . If equipment i s available the
r e p a i r s can be t e s t e d in this m a n n e r : T e n s i o n s p e c i m e n s about 1 inch wide
o r w i d e r a r e cut a c r o s s the r e p a i r and t e s t e d ; the resulting s t r e n g t h values
are c o m p a r e d t o s i m i l a r t e s t s on u n r e p a i r e d m a t e r i a l f r o m the s a m e panel.
If f a i l u r e s o c c u r a t the s p e c i m e n g r i p s i t w i l l b e n e c e s s a r y t o u s e a necked
s p e c i m e n , and possibly to u s e hardwood i n s e r t s in the c o r e a t the g r i p s .
Edgewise c o m p r e s s i o n o r flexure t e s t s a r e s o m e t i m e s u s e d f o r evaluation
of r e p a i r s .
b. R e p a i r s to actual p a r t s (of the type l a t e r to be r e p a i r e d ) that have
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
been r e j e c t e d f o r f u r t h e r u s e b e c a u s e of e x c e s s i v e damage o r s o m e other
reason. T h e s e r e p a i r s may then be carefully inspected by e x p e r i e n c e d
p e r s o n n e l and can be l a t e r t o r n a p a r t t o o b s e r v e the quality of the joints o r
of r e p l a c e m e n t m a t e r i a l .
16-2

___-- -__-- _. __.
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0348223 765 m
16.3 CLASSES O F REPAIR
It is s o m e t i m e s n e c e s s a r y o r m o r e convenient to i n s t a l l a t e m p o r a r y
r e p a i r o v e r m i n o r damage and l a t e r r e p l a c e i t by a permanent r e p a i r .
T h e s e t e m p o r a r y o r e m e r g e n c y r e p a i r s a r e n o r m a l l y devised to f i t the
application and t h e r e f o r e a r e not c o n s i d e r e d in this Handbook. The r e p a i r s
shown f o r f r a c t u r e s completely through the p a r t may' be f u r t h e r subdivided
according to a c c e s s i b i l i t y of the p a r t f r o m both s i d e s o r f r o m one side.
R a d o m e s a r e usually removed f o r r e p a i r u n l e s s they a r e readily a c c e s s i b l e
f r o m both s i d e s . However, s t r u c t u r a l panels s u c h as wing s u r f a c e s , s a n d -
wich f l o o r s , and bulkheads m u s t often be r e p a i r e d i n place, and s o m e t i m e s
by working f r o m one side only. The r e p a i r s shown in this Handbook f o r
r a d o m e s a r e b a s e d on the presumption that both s i d e s of the sandwich radome
a r e a c c e s s i b l e . Some of the r e p a i r s to s t r u c t u r a l sandwich p a n e l s , however,
w e r e designed s o that the r e p a i r can be completed when only one side of the
p a r t is a c c e s s i b l e . If both s i d e s a r e a c c e s s i b l e , the s a m e p r o c e d u r e can be
followed; however, additional optional techniques a r e shown f o r a l t e r n a t e
use.
F o r convenience in presentation and f o r efficiency in designating r e p a i r s

t o sandwich c o n s t r u c t i o n s , damages a r e divided into groups o r cl.asses
according to s e v e r i t y and possible effect upon the s t r u c t u r e . The following
c l a s s e s a r e u s e d in p r e s e n t a t i o n of the r e p a i r techniques in t h i s Handbook.
C l a s s 1 : Dents, s c a r s , s c r a t c h e s , o r e r o s i o n in the f a c i n g s , not

accompanied by a puncture o r a f r a c t u r e .
C l a s s 2: P u n c t u r e s o r f r a c t u r e s in one facing only, possibly accompanied

by damage to the c o r e but without damage to the opposite facing.
C l a s s 3: Holes o r damage extending completely through the sandwich,

affecting both facings and the c o r e .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C l a s s 4: E x t e n s i v e damage r e q u i r i n g r e p l a c e m e n t of a complete s a n d -
wich p a r t o r - p a r t s .
16-3
_ _ _______----- ---------
.
Provided by IHS
-- _____ .__
MIL-HDBK-23A CHG NOTICE 3 E 9 7 9 9 9 7 0 0 3 4 8 2 2 2 bT3
16.4 REPAIR O F PLASTIC
SANDWICH PARTS ( r e f . 16-1)
1 6 . 4 . 1 ReDair M a t e r i a l s
16.4. 1.1 G l a s s F a b r i c
The facings of r a d o m e sandwiches a r e m a d e of s e v e r a l l a y e r s of g l a s s

f a b r i c i m p r e g n a t e d and bonded together with a low - p r e s s u r e , t h e r m o s e t t i n g
laminating r e s i n . A v a r i e t y of g l a s s - f a b r i c weaves a r e employed; however,
the r e p a i r of p r a c t i c a l l y all constructions c a n be accomplished with combina-
tions of the following f a b r i c s :
The t h i c k e r f a b r i c s , s u c h a s 181, 162, and 164, a r e n o r m a l l y u s e d for

t h e body of the facings with one o r m o r e l a y e r s of a finer-weave f a b r i c ,
s u c h as 112 o r 128, on the s u r f a c e . In a l l r e p a i r s it is i m p o r t a n t to d e t e r -
m i n e t h e direction of the t h r e a d s i n the o r i g i n a l facings s o that the d i r e c t i o n
of the t h r e a d s in the r e p l a c e m e n t l a y e r s c a n b e m a d e to m a t c h i n each ply.
G l a s s f a b r i c should b e h e a t cleaned and t r e a t e d with one of the finishes

t h a t prevent s e r i o u s l o s s in s t r e n g t h when the p a r t is l a t e r subjected to p r o -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
longed m o i s t conditions.
16.4. 1.2 Resins
Specifications f o r r a d o m e s allow a selection of approved r e s i n s , n o r -

m a l l y of polyester type; but r e g a r d l e s s of the r e s i n u s e d in the o r i g i n a l
f a b r i c a t i o n of a r a d o m e , a r e p a i r can b e accomplished with any one of t h e
approved r e s i n s of the s a m e type i f the e l e c t r i c p r o p e r t i e s of the r e p a i r e d
p a r t a r e s a t i s f a c t o r y . T h e s e r e s i n s can be m a d e to c u r e a t different t e m -
p e r a t u r e s by adjusting the amount and type of c a t a l y s t . E l e v a t e d t e m p e r a -
t u r e s a r e commonly u s e d in curing the r e s i n i n the f a b r i c a t i o n of r a d o m e s ,
as t h e s e t e m p e r a t u r e s r e d u c e the t i m e r e q u i r e d f o r complete c u r e . E l e v a t e d -
t e m p e r a t u r e curing f a c i l i t i e s m a y not be readily available a t r e p a i r s t a t i o n s ;
t h e r e f o r e c a t a l y s t s m u s t b e chosen t h a t w i l l p r o m o t e complete c u r e at r o o m
t e m p e r a t u r e in a reasonably s h o r t time. The combinations of r e s i n s (of
v a r i o u s v i s c o s i t i e s ) and c a t a l y s t s y s t e m s given i n r e f e r e n c e (16-1) a r e s u g -
g e s t e d ; however, t h e r e a r e o t h e r combinations that will give equally good
results.
16-4

__ _____ ____. __
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 7 9 9 7 0 0148223 538
\
L
In working with polyester resins, catalysts, p r o m o t e r s , and such
solvents as acetone ( n e c e s s a r y t o clean equipment), l o c a l safety regulations
as to fire and health h a z a r d s must be followed. T h e r e s i n s should be s t o r e d
i n c l o s e d m e t a l c o n t a i n e r s in a cool place. C a t a l y s t s , p r o m o t e r s , and s o l -
vents a r e v e r y r e a c t i v e and should be s t o r e d in the original tight c o n t a i n e r s ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
i s o l a t e d f r o m one another in a cool place.
Never m i x the c a t a l y s t and p r o m o t e r together a s

they a r e explosively r e a c t i v e as a m i x t u r e .
Always m i x the p r o m o t e r with the r e s i n f i r s t and
then add the c a t a l y s t to the m i x t u r e . Do not
inhale the fumes during mixing.
16.4.2 P r e p a r i n g Parts f o r Repair
I 16.4.2.1 Radomes
R a d o m e s r e p r e s e n t the principal application of plastic sandwich in a i r -

c r a f t . They a r e n o r m a l l y r e m o v e d f r o m the a i r c r a f t p r i o r to cleaning and
p r e p a r i n g the p a r t f o r the r e p a i r . On r a d o m e s that cannot be removed, the
a r e a immediately around the damage m u s t be cleaned while the radome i s
i n place.
16.4.2.2 Blankets and S e a l s
On l a r g e r e p a i r s i t is n e c e s s a r y to apply a uniformly distributed p r e s -

s u r e to i n s u r e contact. This is b e s t accomplished by using a thin, i m p e r -
vious blanket of polyvinyl alcohol s h e e t , vinylite, o r cellophane. The f i r s t
two m a t e r i a l s can be s t r e t c h e d and m a d e to conform to s u r f a c e s of c o m -
pound c u r v a t u r e , w h e r e a s the l a s t cannot and t h e r e f o r e can only b e used on
single c u r v a t u r e s . The s e a l around the edges of blankets c a n be provided
by using p r e s s u r e - s e n s i t i v e cellophane tape o r a thin rope of a soft sealing
compound. The sealing compound is most p r a c t i c a b l e if the edges of the
blanket a r e likely to be wrinkled. It can be removed and r e u s e d .
16-5

. _ ~
~. ~~ ~ _ _
[IL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 O 3 4 8 2 2 4 474 m
b
c 16.4.2.3 P a r t i n g Films and Compounds
When it is n e c e s s a r y to use a mold t o rebuild a portion of a plastic

sandwich, the s u r f a c e of the mold m u s t be t r e a t e d in s o m e m a n n e r t o p r e -
vent adhesion of the r e s i n . If the mold s u r f a c e is of double c u r v a t u r e ,
s e v e r a l coatings of a good parting compound w i l l give the d e s i r e d r e s u l t s .
On the convex s i d e of compound-curvature molds of polyvinyl alcohol o r

vinylite parting film c a n often be s t r e t c h s d wrinkle - f r e e , and cellophane
w o r k s v e r y w e l l on molds of s i n g l e - c u r v a t u r e . If the r e p a i r is done i n
p l a c e , c a r e m u s t be e x e r c i s e d to avoid paint r e m o v e r s and stripping c o m -
pounds n o r m a l l y u s e d on the m e t a l p a r t of the plane f o r removing finish,
S o m e of t h e s e m a t e r i a l s have been found to p e n e t r a t e the facing of the
r a d o m e and m a y possibly have a n a d v e r s e effect on i t s d i e l e c t r i c p r o p e r t i e s
o r s t r e n g t h . Parts that a r e removed f o r r e p a i r m u s t be handled with c a r e
to avoid a b r a s i v e and puncture damage f r o m contact with metal objects,
p a r t s r e m o v e d f r o m the a i r c r a f t f o r r e p a i r , o r f r o m stacking on a rough con-
c r e t e floor. Radomes should always b e supported on padded supports o r
should b e supported f r o m the mounting holes provided f o r that purpose.
The a r e a to be r e p a i r e d is first cleaned with s o a p and w a r m w a t e r .

After it is d r y , the a r e a is carefully inspected f o r e x c e s s i v e l a y e r s of paint.
T h e paint is removed by wet o r d r y sanding methods; o r i f equipment is
-
available, by light s e e d blasting.
16.4.3 R e p a i r Techniques
16.4.3. 1 Class 1 Repairs
S c a r s , s c r a t c h e s , s u r f a c e a b r a s i o n , or r a i n e r o s i o n m a y be r e p a i r e d
as follows: Apply one o r m o r e c o a t s of r e s i n , catalyzed to r o o m t e m p e r a -
t u r e , t o the a b r a d e d s u r f a c e (number of coats depends upon the s e v e r i t y of
the a b r a s i o n ) . S m a l l f r a c t u r e s m a y be filled with a putty m a d e f r o m r o o m -
t e m p e r a t u r e - s e t t i n g r e s i n and s h o r t g l a s s f i b e r s . Over this coated s u r f a c e
apply a s h e e t of cellophane t h a t extends 2 o r 3 inches beyond the painted
s u r f a c e ; after it is taped in p l a c e , w o r k out all a i r bubbles and e x c e s s i v e
r e s i n with t h e hand o r a r u b b e r squeegee. The r e s i n can then be allowed t o
c u r e at r o o m t e m p e r a t u r e , o r , i f n e c e s s a r y , the c u r e can be hastened by
the u s e of i n f r a r e d bulbs o r hot sandbags. Occasionally, on s m a l l p a r t s ,
the whole p a r t c a n be put i n a n oven s e t at 100" C (212" F ) to hasten the
cure. After the r e s i n h a s been c u r e d , the cellophane i s r e m o v e d , the
e x c e s s r e s i n i s sanded off, and the whole r e p a i r e d a r e a is lightly sanded
p re p a r a t o r y t o ref ini shing.
16-6
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
- - - - -
/-
y

____ _-
=
.
MIL-HDBK-23A C H G N O T I C E 3 '7999970 0 1 4 8 2 2 5 3 0 0
If the s u r f a c e a b r a s i o n s , s c r a t c h e s , o r s c a r s a r e deep enough to

s e r i o u s l y affect the s t r e n g t h of the facing (usually to m o r e than the f i r s t ply
of f a b r i c ) , they should b e r e p a i r e d in the following m a n n e r : Sand the d a m -
aged a r e a e i t h e r by hand o r with a flexible d i s k s a n d e r to a smooth contour
as shown i n figure 16-1. Sand to a distance of at l e a s t 100 times the depth
of m a t e r i a l removed. Coat the sanded a r e a with one coat of r o o m -
t e m p e r a t u r e - s e t t i n g r e s i n and apply pieces of g l a s s f a b r i c soaked in r e s i n
t o a r e s i n content of about 50 percent. Lay t h e s e pieces of f a b r i c i n place
i n t h e sanded d e p r e s s i o n as shown in figure 16-1. Tape cellophane in place
o v e r the r e p a i r and w o r k out e x c e s s r e s i n . After the r e s i n h a s c u r e d , the
s u r f a c e of the r e p a i r is sanded down to the o r i g i n a l s u r f a c e of the facing.
16.4.3.2 Class 2 Repairs
Damages that extend completely through one facing of the sandwich and
into the c o r e r e q u i r e r e m o v a l of the damaged c o r e and r e p l a c e m e n t of the
damaged facing in s u c h a m a n n e r that n o r m a l s t r e s s e s can b e c a r r i e d o v e r
the a r e a . F i g u r e 1 6 - 2 shows one method f o r accomplishing this type of
r e p a i r . The damaged portion i s carefully t r i m m e d out to a c i r c u l a r o r oval
s h a p e and the c o r e removed completely to the opposite facing. Caution m u s t
be e x e r c i s e d not to damage the opposite facing o r to s t a r t delaminations
between t h a t facing and the c o r e around the damage. The damaged facing
around the t r i m m e d hole is then s c a r f e d back carefully by using a flexible
d i s k s a n d e r , a belt or rotating pad s a n d e r , o r by hand, to a distance of at
l e a s t 100 t i m e s the facing t h i c k n e s s . This s c a r f i n g operation m u s t be done
a c c u r a t e l y to a uniform t a p e r and usually takes a little p r a c t i c e before
acceptable s c a r f s a r e obtained. Contour lines produced by the individual
plies of f a b r i c in the sanding operation can be used to judge the a c c u r a c y of
the s c a r f e d s u r f a c e .
T h e sanding operation on l a m i n a t e s r e i n f o r c e d with

g l a s s f a b r i c gives off a fine dust t h a t m a y c a u s e
s k i n i r r i t a t i o n . In addition, breathing a n e x c e s s i v e
amount of this dust m a y b e i n j u r i o u s ; t h e r e f o r e
precautions as to skin and r e s p i r a t i o n protection
m u s t be observed. --`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
A piece of r e p l a c e m e n t c o r e m a t e r i a l ( o r a suitable substitute) equal in

thickness to the original c o r e m a t e r i a l i s cut to f i t snugly in the t r i m m e d
hole.
16-7
I_
- -
,
--
- Y
_-
The g l a s s - f a b r i c laminations f o r the facing r e p a i r a r e then p r e p a r e d ,

with the l a r g e s t piece being cut to the exact shape of the outside of the
s c a r f e d a r e a . The s m a l l e s t piece is cut s o that it overlaps the s c a r f e d a r e a
by i t s proportionate amount, depending on the n u m b e r of plies i n the r e p a i r ,
and the i n t e r m e d i a t e pieces are cut to have equal o v e r l a p s . A convenient
m e a n s of p r e p a r i n g t h e s e pieces i s to b r u s h - s p r e a d the r e s i n on the pieces
of f a b r i c and sandwich the s p r e a d f a b r i c between two s h e e t s of c o l o r e d cello-
phane. T h e pieces are then cut t o shape without the u s u a l fraying a t the
edges. The r e s i n content of the f a b r i c should be about 50 percent.
When a l l of the pieces a r e r e a d y f o r a s s e m b l y , the opening f r o m which

the damaged c o r e was r e m o v e d is coated on a l l s i d e s and bottom with r o o m -
t e m p e r a t u r e - s e t t i n g r e s i n . The piece of c o r e that i s to be i n s e r t e d i s like-
w i s e c o a t e d on all s i d e s , including top and bottom s u r f a c e s , and i n s e r t e d in
the hole. T h e pieces of f a b r i c a r e then laid in place by f i r s t removing the
cellophane s h e e t f r o m one side of the f a b r i c , placing the exposed f a b r i c in
position on the r e p a i r , and then removing the second cellophane s h e e t . The
whole a r e a is then c o v e r e d by a piece of cellophane and carefully worked down
t o r e m o v e as m u c h e x c e s s r e s i n and a i r a s possible. Light p r e s s u r e is
applied t o the cellophane by m e a n s of s a n d b a g s , taping (if the r e p a i r i s on a
convex a r e a ) , o r a vacuum blanket, i f facilities p e r m i t .
After the r e p a i r has c u r e d , i t is lightly sanded t o contour .it to the -

o r i g i n a l s h a p e , and it i s then r e a d y f o r refinishing.
An a l t e r n a t e method that may be u s e d f o r c l a s s 2 r e p a i r s i s the "stepped-

joint" method, d e s c r i b e d u n d e r c l a s s 3 r e p a i r s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Damages that are completely through the sandwich m a y b e r e p a i r e d by

two methods: (1) The s c a r f - j o i n t method ( s i m i l a r t o that d e s c r i b e d f o r
c l a s s 2 d a m a g e ) , and (2) the stepped-joint method d e s c r i b e d later. The
s c a r f e d method is n o r m a l l y u s e d on s m a l l punctures up t o 3 o r 4 inches in
m a x i m u m dimension, and i n facings m a d e of thin f a b r i c s (which a r e difficult
to peel). T h e stepped-joint method is often employed on l a r g e r r e p a i r s to
facings composed of thick f a b r i c s .
16-8

MIL-HDPK-23A C H G N O T I C E 3 9979970 0148227 1 8 3 =
T h e details of the s c a r f e d method a r e shown in figure 16-3. They consist

of t r i m m i n g out the d a m a g e d portion and proceeding a s with c l a s s 2 damage,
except that the opposite s i d e of the sandwich is provided with a t e m p o r a r y
mold o r block to hold the c o r e in place during the f i r s t step. After the f i r s t
facing r e p a i r is c u r e d completely, the mold and the s h i m (which t e m p o r a r i l y
r e p l a c e d the facing on the opposite side) a r e removed and the r e p a i r is c o m -
pleted by repeating the p r o c e d u r e u s e d in the first s t e p . Typical s t e p s in
making this type of r e p a i r a r e shown in figure 16-3.
By using the stepped-joint method shown in figure 16-4, the damaged

portion is t r i m m e d a s b e f o r e to a round o r oval shape o r to a r e c t a n g u l a r o r
s q u a r e shape ( p r e f e r a b l y having rounded c o r n e r s ) . T h e t h i c k n e s s e s of the
individual plies in the facings a r e d e t e r m i n e d , f o r choice of replacement
f a b r i c s , f r o m t h e portions removed; the total o v e r l a p of the stepped joint is
computed f r o m the number of plies in one facing, minus one, t i m e s 1 - 1 / 2
inches. This o v e r a l l s i z e i s then m a r k e d on the sandwich. The m a r k i n g
can be done with cellophane tape o r by lightly s c r a t c h i n g the s u r f a c e . The
o u t e r l a y e r of f a b r i c only i s then cut with a s h a r p knife o r a specially p r e -
p a r e d c u t t e r along t h e s e lines.
1 CAUTION
Do not cut through m o r e than one l a y e r . If the

l a y e r of f a b r i c underneath i s s c r a t c h e d , the
s t r e n g t h of the r e p a i r will s u f f e r .
Using a knife blade, the outer f a b r i c l a y e r can be lifted and carefully

peeled away f r o m the l a y e r underneath until the e n t i r e s h e e t is removed;
this leaves a clean-cut s t e p round the a r e a . The p r o c e s s i s then r e p e a t e d ,
w i t h the cut being m a d e at a distance of 1 - 1 / 2 inches inside the original
s t e p , as shown in figure 16-4. E a c h consecutive l a y e r of g l a s s - f a b r i c l a m -
ination s h a l l be removed in this m a n n e r except the l a s t one (bonded to the
c o r e ) , which i s exposed f o r an a r e a approximately 1 - 1 / 2 inches wide around
the t r i m m e d hole, T h i s s u r f a c e i s then lightly sanded. A piece of c o r e
material of identical thickness to t h a t in the sandwich i s p r e p a r e d of the
s a m e m a t e r i a l ( o r an approved substitute) and of a s i z e to provide a snug fit
i n t h e t r i m m e d hole. G l a s s - f a b r i c s h e e t s of a p p r o p r i a t e thickness a r e then
cut slightly too l a r g e (approximately an inch o r two o v e r s i z e ) f o r e a c h of
the s t e p s i n the r e p a i r . A mold and s h i m combination i s now p r e p a r e d for
t h e opposite side of the sandwich to p r e s e r v e the contour while the f i r s t fat-
ing is being r e p a i r e d .
16-9
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

~-
MIL-HDBK-23A CHG N O T I C E 3 9999770 0 3 4 8 2 2 8 OLT
L
e
After the mold and s h i m have been t e m p o r a r i l y s e c u r e d in place by
clamping, propping, o r lashing, the damaged a r e a i s ready f o r the first s t e p
i n rebuilding. T h e r e p l a c e m e n t c o r e piece is coated with r e s i n on all edges
and the top s u r f a c e only, leaving the bottom s u r f a c e (next t o the t e m p o r a r y
s h i m ) uncoated. It is then i n s e r t e d in place above the t e m p o r a r y s h i m . The
g l a s s - f a b r i c s h e e t s f o r r e p a i r i n g the facing a r e now i m p r e g n a t e d with r e s i n
t o a resin content of about 5 0 p e r c e n t , and the s m a l l e s t one is laid in place
o v e r the r e p l a c e d c o r e . It is then t r i m m e d with s c i s s o r s to the exact shape
of the t r i m m e d hole. After the t r i m m e d portion h a s been r e m o v e d , s u c c e s -
s i v e plies of g l a s s f a b r i c a r e laid in place and t r i m m e d , j u s t as was done
f o r the f i r s t ply. An e x t r a l a y e r of 112 cloth is then applied o v e r the r e p a i r
and t r i m m e d so t h a t it laps about 1 / 2 inch o v e r the undamaged facing. The
a r e a is then c o v e r e d with cellophane, and the e x c e s s r e s i n and air a r e worked
out as d e s c r i b e d e a r l i e r .
16.4.4 Special Considerations
Sandwich p a r t s in a i r c r a f t a r e o r d i n a r i l y thought of a s being uniform in

thickness and having a c o r e of honeycomb m a t e r i a l , o r a n a t u r a l c o r e s u c h
as baisa. Some p a r t s , however, have a foamed-in-place c o r e ; the p a r t s ,
i n addition t o being v e r y i r r e g u l a r in s h a p e , m a y v a r y in thickness. T h e s e
p a r t s , b e c a u s e of the n a t u r e of t h e i r u s e , a r e built to v e r y exacting t o l e r -
--.
ances on both the facing and the o v e r a l l thickness. Sandwiches of this type
s o m e t i m e s develop voids o r delaminations a t the i n t e r f a c e between the f a c -
ing and the foamed-in-place c o r e , c a u s e d by a blow f r o m a blunt object.
T h e s e voids m a y b e r e p a i r e d by injecting a small quantity of r o o m -
t e m p e r a t u r e - c a t a l y z e d r e s i n by m e a n s of a hypodermic needle and s y r i n g e .
Two 1/32-inch holes a r e d r i l l e d i n the facing at d i a m e t r i c a l l y opposite s i d e s
of the void area. T h e r e s i n is injected into one hole until it s t a r t s to exude
f r o m the o t h e r . Slight p r e s s u r e is then applied by m e a n s of a hot sandbag
o v e r the void to r e m o v e e x c e s s r e s i n and to i n s u r e contact between the f a c -
ing and the c o r e while the r e s i n is curing.
16-10
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-_
MIL-HDBK-23A C H G N O T I C E 3 m 7999770 0148229 T 5 6 m
c
T h e r e a r e a few applications of plastic-faced sandwiches in which a c c e s s
f o r r e p a i r is possible only f r o m the outside. In t h e s e p a r t s "blind r e p a i r s "
must b e employed in the r e p a i r of c l a s s 3 damages. R e p a i r s of this type
have been m a d e by using a plastic backing plate and a technique f o r its
attachment s i m i l a r t o that d i s c u s s e d l a t e r f o r the r e p a i r of m e t a l - f a c e d
sandwiches. The backing plate should b e about O . 060 inch thick, and it can
be made of g l a s s f a b r i c and r o o m - t e m p e r a t u r e - c u r i n g r e s i n by working out
the e x c e s s r e s i n f r o m the impregnated f a b r i c while it is under a cellophane
cover sheet. If the p a r t to b e r e p a i r e d is c u r v e d , the backing plate should
be laminated on a cellophane-covered s u r f a c e of the p r o p e r c u r v a t u r e n e a r
the damaged a r e a o r at the s a m e location on a s i m i l a r undamaged p a r t . It
should be noted that the damage m u s t be t r i m m e d t o a n oval shape s o that
the backing plate can be i n s e r t e d through the t r i m m e d hole. After the back-
ing plate h a s been bonded in place with r e s i n , the c o r e and s u r f a c e patch can
be f a b r i c a t e d a s shown i n figure 1 6 - 2 .
16.5 REPAIR O F ADHESIVE -BONDED
M E T A L SANDWICH (ref. 16-2)
16.5. 1 R eDair M a t e r i a l s
16.5. I . 1 Aluminum Alloy Sheet
The s t r o n g e r alloys of aluminum, s u c h a s 7075-T6, 2024-T3, o r

2014-T6, a r e commonly u s e d in the r e p a i r of facings for s t r u c t u r a l s a n d -
wich p a r t s having aluminum facings.
Occasionally, m a g n e s i u m alloy s h e e t s and s t a i n l e s s s t e e l s h e e t s a r e

u s e d f o r facings on miscellaneous sandwich p a r t s . F o r the p r e s e n t , when
t h e s e m a t e r i a l s a r e encountered i n r e p a i r , the r e p a i r to m a g n e s i u m facings
can be 'accomplished with aluminum alloy s h e e t s i f n e c e s s a r y . If a m a j o r
r e p a i r is involved, the p a r t should b e replaced.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
16-11

MIL-HDBK-23A CHG N O T I C E 3 = 70 0 1 4 8 2 3 0 778 P
16.5.1.2 Adhesives
Metal-faced sandwich p a r t s a r e n o r m a l l y bonded with c o m m e r c i a l l y

available m e t a l - t o - m e t a l adhesives that r e q u i r e high t e m p e r a t u r e s t o c o m -
plete t h e c u r e , and s o m e t i m e s r e q u i r e in addition the application of r a t h e r
high p r e s s u r e s . Neither of t h e s e r e q u i r e m e n t s is e a s i l y met i n field r e p a i r ;
t h e r e f o r e , adhesives that w i l l c u r e a t r o o m t e m p e r a t u r e o r slightly h i g h e r ,
with the application of a m i n i m u m of p r e s s u r e , a r e the only ones t h a t c a n be
p r a c t i c a l l y employed. At the p r e s e n t t i m e only the adhesives b a s e d on the
u s e of epoxy r e s i n s a p p e a r to s a t i s f y t h e s e r e q u i r e m e n t s . However, t h e r e
undoubtedly a r e o t h e r combinations that will prove equally s a t i s f a c t o r y .
S e v e r a l companies a r e now manufacturing kits u s e d f o r field mixing of

the epoxy adhesives in r e p a i r work. T h e p r o p e r amount of c a t a l y s t is con-
tained in a n ampoule and c a n b e f o r c e d into a l a r g e plastic bag containing
the epoxy w h e r e it is m i x e d thoroughly b e f o r e being u s e d ,
16.5. 1.3 Core Materials
Aluminum-faced sandwich p a r t s n o r m a l l y have c o r e s of ,,oneycomb o r

end-grain b a l s a . In r e p a i r i n g sandwiches of t h i s type , it is advisable when-
e v e r p o s s i b l e t o u s e the s a m e m a t e r i a l f o r t h e r e p l a c e m e n t of the c o r e i n
the damaged a r e a ; however, s i n c e the c o r e in a s t r u c t u r a l sandwich having
aluminum facings i s choc en p r i m a r i l y f o r s t r e n g t h r e q u i r e m e n t s , any
r e p l a c e m e n t m a t e r i a l that s a t i s f i e s t h e s e s t r e n g t h r e q u i r e m e n t s will be
acceptable in a n e m e r g e n c y , provided it i s equally durable. Plywood of the
e x t e r i o r type h a s been found to be suitable e m e r g e n c y m a t e r i a l f o r replacing
e i t h e r aluminum honeycomb o r e n d - g r a i n b a l s a i n s m a l l r e p a i r s .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
16-12

__- - _ _ _ ~ _ _ _
16.5.2 R e p a i r Techniques
Dents, s c a r s , o r f r a c t u r e s not exceeding 1 / 4 inch i n l a r g e s t dimension

in aluminum facings m a y b e r e p a i r e d by the u s e of a suitable f i l l e r s u c h a s
a viscous epoxy r e s i n . The dent, a f t e r being cleaned with fine ( 3 0 0 g r i t )
aluminum oxide paper and acetone is completely filled with a viscous r o o m -
t e m p e r a t u r e - s e t t i n g epoxy r e s i n . If the s t r u c t u r e is to be exposed in a
m a r i n e a t m o s p h e r e the s u r f a c e s h a l l b e t r e a t e d with a chemical f i l m ,
MIL-C-5541, p r i o r t o filling with r e s i n . After the r e s i n i s c u r e d at room
t e m p e r a t u r e f o r s e v e r a l h o u r s the e x c e s s is removed by m e a n s of a s h a r p
c h i s e l and aluminum oxide paper t o the original m e t a l s u r f a c e . The i n s e r t
of epoxy r e s i n is then completely c u r e d by means of a hot sandbag o r an
i n f r a r e d bulb a t a t e m p e r a t u r e of about 93 C (200" F ). 16 the damage h a s
O
been accompanied by a s m a l l f r a c t u r e of t h e aluminum facing s o that t h e r e

might b e danger of the s t r e n g t h being i m p a i r e d , the a r e a around the filled
hole is then recleaned and a s u r f a c e patch applied by means of an epoxy
r e s i n and a s i m i l a r c u r i n g cycle.
F i l l e d r e p a i r s of this type t o facings of clad 2024-T3 aluminum have

been exposed to m o r e than 7 5 cycles of 24 hours in an oven a t 1 0 4 " C
(220' F ), followed by 24 h o u r s under w a t e r a t room t e m p e r a t u r e , with no
a p p a r e n t effect on the r e p a i r . This e x p o s u r e , however, did produce s o m e
c o r r o s i o n on the unpainted aluminum f a c i n g s .
F r a c t u r e s o r punctures in one facing and p a r t i a l damage to the c o r e of

a sandwich p a r t m a y b e r e p a i r e d by s e v e r a l different methods depending on
the s i z e of the damage and on the s t r e n g t h , a e r o d y n a m i c , and sonic fatigue
r e s i s t a n c e r e q u i r e m e n t s of the a r e a involved. Typical damage to one f a c -
ing and the honeycomb c o r e i s shown i n figure 16-5.
16- 13
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_____
MIL-HDBK-23A CHG N O T I C E 3 9 7 9 9 9 7 0 O348232 5 4 0
1 6 . 5 . 2 . 2 . 1 Removal of Damaged Facing and C o r e . --After location of

the complete damaged a r e a by tapping o r o t h e r nondestructive t e s t m e t h o d s ,
t h e a r e a should be outlined with m a r k i n g pencil and the c e n t e r coordinates
d e t e r m i n e d . T h e damaged facing and that portion of the c o r e which i s d a m -
aged is then r e m o v e d , usually in the f o r m of a c i r c u l a r a r e a . If the damage
is i n t h e shape of a long, n a r r o w r u p t u r e , a n a r e a including the damage can
be r e m o v e d i n which the r a t i o of length to width is approximately 2 to 1, and
the c o r n e r s p r e f e r a b l y have a r a d i u s of at l e a s t 1 inch. T h e damaged a r e a
can be removed by the u s e of hole s a w , r o u t e r , o r r o t a r y file bits in an
e l e c t r i c d r i l l o r pneumatic r o u t e r a s shown i n f i g u r e s 16-6 and 16-7. T e m -
plates with s t a n d a r d - s i z e holes and shapes to guide these tools a c c u r a t e l y
can be f a b r i c a t e d of plywood, m e t a l , o r plastic l a m i n a t e s .
The option of routing of the c o r e to the adhesive f i l l e t line on the opposite

f a c e o r to r e m o v e the c o r e to only its damaged depth will depend on the type
of r e p a i r t o be f a b r i c a t e d .
. A f t e r r e m o v a l of the damaged a r e a , t h e edges of the hole should be

carefully d e b u r r e d using a hand file. Any loose p a r t i c l e s in the c o r e cavity
should then be blown out.
C a r e should b e taken by w e a r i n g safety g l a s s e s

throughout this routing operation.
If t h e r e is a possibility that any oils o r o t h e r contaminates might have

e n t e r e d the c o r e cavity, it should be wiped out with a c l e a n cloth s a t u r a t e d
with t r i c h l o r o e t h y l e n e , and then f o r c e d r i e d with a h e a t l a m p .
I WARNING 1
Trichloroethylene is not f l a m m a b l e , but caution

should b e taken to avoid inhaling the v a p o r s as
they have a cumulative toxic effect.
F o r s o m e types of r e p a i r requiring aerodynamically smooth s u r f a c e s ,

s t e p cutting (fig. 16-8), of the facing to one-half of its thickness is r e q u i r e d .
This s t e p cutting can be done, taking g r e a t c a r e , by the u s e of a r o u t e r and
end mill bit, stand, and template as shown in f i g u r e 16-7. Scarfing of the
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
facings might a l s o be done us-ing s i m i l a r r o u t e r s and templates with a s c a r f -

type f a c e patch, The technique f o r p r e p a r i n g long s c a r f s in t h e s e thin f a c -
ings will, however, need to be carefully developed.
16-14
__--------
I__-- . -
z
Provided by IHS
.
Undercutting of the c o r e surrounding the r e p a i r hole is u s e d in c e r t a i n

r e p a i r procedures to obtain b e t t e r bonding of plastic f i l l m a t e r i a l s i n r e p l a c -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
ing the damaged c o r e i n the sandwich panel. T h i s undercutting of the c o r e

c a n be done with s p e c i a l undercutting r o u t e r bits o r by the u s e of a hand
undercutting tool of the type shown in figure 16-9.
1 CAUTION 1
Throughout the machining operations r e q u i r e d to
remove the damaged skin and c o r e , e x t r e m e c a r e
should be taken not to s c r a t c h o r o t h e r w i s e d a m -
age the surrounding s u r f a c e s . P a p e r and plastic
f i l m s can be taped in place to protect t h e s e
surfaces.
1 6 . 5 - 2 . 2 . 2 Replacement of Core. - - T h e method of r e p l a c e m e n t of the

damaged a r e a of the honeycomb o r o t h e r c o r e m a t e r i a l v a r i e s among the
different r e p a i r methods shown i n f i g u r e 16-10.
I n s o m e r e p a i r o p e r a t i o n s , c o r e s of the s a m e type a s the o r i g i n a l c o r e

a r e fabricated to s h a p e , keeping the c o r e ribbon direction the s a m e as i n
the original c o r e , and then bonded in place using epoxy adhesives of the
type to give equivalent p e r f o r m a n c e t o t h a t of the o r i g i n a l adhesive. Balsa
o r g l a s s - f a b r i c honeycomb c o r e s a r e n o r m a l l y c o n s i d e r e d e a s i e r to f a b r i -
c a t e to shape on the job, and they a r e , t h e r e f o r e , s o m e t i m e s u s e d in the
r e p a i r of aluminum honeycomb panels.
F o r the s m a l l e r c o r e d a m a g e s , epoxy r e s i n fills a r e u s e d to r e p l a c e the

c o r e s . T h e s e epoxy r e s i n fills m a y be modified, in addition to the r e q u i r e d
c a t a l y s t s , with polysulfide o r polyamide r e s i n s , o r with microballoons o r
low -dencity insulating m a t e r i a l s to lower the density, give g r e a t e r flexibility,
and to lower the s t r e s s concentration in the a r e a of the r e p a i r .
When the c o r e f i l l is a l s o t o be u s e d in the s a m e r e p a i r f o r a s u r f a c e

f i l l t o replace the removed s k i n , m i l l e d g l a s s fibers o r flakes o r aluminum
d u s t a r e s o m e t i m e s u s e d in combination with the epoxy r e s i n fills to i m p a r t
a d d i t i o n d s t r e n g t h and r e s t r a i n shrinkage of the f i l l m a t e r i a l .
16-15
!

L
_ _ _ _ _ _ _ I _
MIL-HDBK-23A
------
CHG N O T I C E 3
_ _ _
9999970 0348234 3 3 3
~
=
These f i l l m a t e r i a l s m a y b e placed into the c o r e cavity by the u s e of a
caulking o r s e a l a n t gun, a s p a t u l a , or poured into place using plastic molded
"dams". Thorough working of the r e s i n f i l l with spatula o r rod should be
done t o remove all e n t r a p p e d air. S m a l l holes a r e s o m e t i m e s punctured
into the c o r e surrounding the c o r e cavity to p e r m i t s o m e of the entrapped
air t o escape. T h e s u r f a c e surrounding the c o r e cavity should be protected
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
with polyester o r polyvinyl tape o r film to prevent e x c e s s adhesive f r o m

adhering to it.
If the c o r e f i l l is m a d e f l u s h with o r slightly above the s u r f a c e of the

s k i n , it c a n be r e t a i n e d i n place and the n e c e s s a r y p r e s s u r e applied by t a p -
ing o v e r it with p o l y e s t e r o r polyvinyl tape.
The epoxy r e s i n f i l l can be c u r e d a t r o o m t e m p e r a t u r e s , o r by the u s e

of heat lamps, hot sandbags, o r by the u s e of t h e r m o s t a t i c a l l y controlled
h e a t blankets.
F o r those r e p a i r s of l a r g e r holes i n which it is inconvenient to u s e a

face patch b e c a u s e of aerodynamic smoothness r e q u i r e m e n t s of the a r e a ,
c o r e and facing c a n be r e p a i r e d using a combination of g l a s s f a b r i c and
epoxy laminating r e s i n . This r e p a i r is done using undercut c o r e . P r e c u t
epoxy r e s i n - s a t u r a t e d g l a s s cloth disks a r e worked into place i n the routed
hole, rubbing out e a c h ply smooth to remove a i r bubbles a s shown in the
f i g u r e . Special c a r e should be taken that the final plies i n the c o r e cavity
f i t well against the overlapping skin. F i n a l r e s i n f a b r i c plies to f i l l the
skin hole a r e then i n s e r t e d i n the hole, rubbing out e a c h individual ply in
place. A w i r e s c r e e n is then placed o v e r the r e p a i r , and any e x c e s s r e s i n
and air worked out.
This is followed by placing a polyvinyl s h e e t o v e r the r e p a i r and the

additional working out of e x c e s s r e s i n . After a p r e l i m i n a r y room t e m p e r a -
t u r e c u r e , the polyvinyl s h e e t is r e m o v e d , and the laminate i s given a final
c u r e with h e a t l a m p s . The r e p a i r is s u r f a c e d smooth and then given a final
s u r f a c e coating.
Another method of replacing the c o r e , and a l s o a t the s a m e t i m e bonding

on a facing patch, is to u s e a patch m a d e as shown i n f i g u r e 16-10E f r o m a
s e c t i o n of sandwich panel having the s a m e construction and c u r v a t u r e a s
t h a t of the r e p a i r a r e a . Epoxy r e s i n adhesive i s u s e d f o r bonding this patch
i n place, following the g e n e r a l p r o c e d u r e f o r cleaning the s u r f a c e s and
applying curing p r e s s u r e and t e m p e r a t u r e s l i s t e d in s e c t i o n s 1 6 . 5 . 2 . 2 . 3
and 16.5.2.2.5. F o r s t a n d a r d c o n s t r u c t i o n s , t h e s e sandwich patches c a n
be p r e f a b r i c a t e d in s t a n d a r d s i z e s , with the bonding s u r f a c e s t r e a t e d and
p r i m e d so that no c h a m i c a l t r e a t m e n t of the s u r f a c e is r e q u i r e d at the t i m e
of u s e .
16-16
I -
Provided by IHS
________
NIL-HDBK-23A CHG N O T I C E 3 = 9999970 0348235 2 5 T M
16.5.2.2.3 Cleaning of Bonding S u r f a c e s . - - A l l s u r f a c e s t o be bonded

must be cleaned f r e e of all o i l , g r e a s e , wax, paint, and adhesive, and then,
if p o s s i b l e , given a n acid etch.
A light a b r a s i o n with a n a b r a s i v e cloth o r m e t a l wool can be u s e d to

remove old adhesive and paint coatings f r o m the r e p a i r a r e a .
The u s e of a b r a s i v e m a t e r i a l s containing m e t a l
p a r t i c l e s that differ f r o m the m e t a l being cleaned
should be avoided to prevent establishing e l e c t r o -
lytic c o r r o s i o n conditions. Approved cleaning
m a t e r i a l s a r e r e c o m m e n d e d in N A V W E P S
07-1-503, NAV W E P S 01-IA-506, and A i r F o r c e
- -
T.O. 1 1 1. T h e stripping solutions should not
b e allowed to s o a k into the adhesive bond a d j a -
cent to the r e p a i r a r e a s .
Chemical solvents s u c h as methyl ethyl ketone, lacquer t h i n n e r , toluol,

and aliphatic naphtha c a n be u s e d to d e g r e a s e the s u r f a c e s . The solvents
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
a r e wiped on the s u r f a c e s with a s o f t , clean cloth, and carefully wiped off
b e f o r e the solvent d r i e s . A clean cloth is u s e d f o r the final application of
solvent to e a c h a r e a .
Rubber gloves should be w o r n to avoid contact

of solvent with the skin. Aliphatic naphtha
should not be u s e d n e a r s p a r k s o r an open flame.
If the liquid is s p i l l e d on the s k i n , it should be
washed off immediately with c l e a n , c l e a r w a t e r .
S o m e f a b r i c a t o r s follow solvent d e g r e a s i n g by washing with a d e t e r g e n t -

wetting agent w a t e r solution, r i n s i n g , and wiping d r y to f u r t h e r clean the
s u r f a c e . Etching c a n be accomplished by using a s u l f u r i c sodium dichromate
p a s t e . Other f a b r i c a t o r s t r e a t the s u r f a c e s , a f t e r solvent d e g r e a s i n g , by
brushing on a Deoxidine 624 solution to keep the s u r f a c e wet f o r 2 0 m i n u t e s ,
followed by rinsing with a w a t e r - s o a k e d cloth, and wiping d r y . This t r e a t -
m e n t is followed by a brushing with Alodine 600 solution, left on the s u r f a c e
f o r 2 to 5 m i n u t e s , r i n s e d with a w a t e r - s o a k e d cloth, and d r i e d .
16- 17

-
MIL-HBBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0148236 196 m
G r e a t c a r e must be taken t h a t c o r r o s i v e m a t e r i a l s o r w a t e r do not

become entrapped within the r e p a i r a r e a s . W a t e r entering the honeycomb
c o r e w i l l c a u s e s e r i o u s s t r u c t u r a l damage u n d e r f r e e z i n g conditions.
I WARNING I
Hazardous bonding and cleaning m a t e r i a l s should
not be u s e d i n enclosed a r e a . D i r t and g r e a s e
should be removed f r o m all equipment before
r e p a i r w o r k i s begun. F u e l tanks m u s t be emptied
and defumed, and wings s h o r e d to a level position,
i f the r e p a i r w o r k employs a h e a t cycle in any way.
S e v e r a l f a b r i c a t o r s apply a dilute solution of a r u b b e r - b a s e phenolic

adhesive p r i m e r to the bonding s u r f a c e a s a final s t e p in the p r e t r e a t m e n t .
T h e s e p r i m e r t r e a t m e n t s a r e s a i d t o improve peel and s a l t - w a t e r s p r a y
resistance.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
The alumi-num facing patches t h e m s e l v e s , which a r e m o r e convenient to

handle than the a r e a s on the sandwich panel, can be given a complete s u r f a c e
t r e a t m e n t with s u l f u r i c acid-sodium d i c h r o m a t e solution. This etched s u r -
face is p r o t e c t e d until u s e , in s o m e r e p a i r k i t s , by a thin peelable aluminum
foil attached to the s u r f a c e , using a bondable adhesive p r i m e r .
16.5.2.2.4 Bonding of Facing P a t c h , --After r e p l a c e m e n t of the c o r e a s

d e s c r i b e d in section 1 6 . 5 . 2 . 2 . 2 , a facing patch m u s t be s e p a r a t e l y bonded
i n place, except f o r t h o s e r e p a i r s m a d e on s m a l l a r e a s in which the epoxy
r e s i n f i l l is u s e d to r e p l a c e both c o r e and facing, o r f o r those r e p a i r s in
which g l a s s - f a b r i c laminate o r sandwich panel section (fig. 16-10E) has
b e e n u s e d t o r e p l a c e both c o r e and facing.
Five g e n e r a l types of facing patches a r e u s e d , depending upon the s e r v i c e

r e q u i r e m e n t s f o r the sandwich p a r t :
(1) A small, flush plug-type facing patch i n which a m e t a l facing plug is

m e r e l y bonded in the facing hole a f t e r the c o r e h a s been replaced. This
type of patch gives aerodynamic s m o o t h n e s s , but does not r e p l a c e any of the
s t r e n g t h l o s t f r o m the damage to the sandwich p a r t . The plug-type patch
can, after being cleaned, be bonded into place with epoxy r e s i n s using only
minor p r e s s u r e applied by t a p e s , and c u r e d a t r o o m t e m p e r a t u r e s o r by the
use of h e a t l a m p s o r hot sandbags.
16-18
--
I

_--
-
MIL-HDBK-23A CHG N O T I C E 3 9779970 0348237 O22
(2) An o v e r l a p type of m e t a l facing patch with the o u t e r edge s c a r f e d

f o r s t r e n g t h and aerodynamic efficiency. With this type of facing r e p a i r and
with good bonding techniques, p r a c t i c a l l y f u l l s t r e n g t h of the facing c a n be
regained. The o v e r l a p patch is bonded in place o v e r the facing and replaced
c o r e after first cleaning the skin s u r f a c e s and patch. E p o x y - r e s i n adhesives
a r e n o r m a l l y used f o r the bonding b e c a u s e of t h e i r lower p r e s s u r e and c u r e
t e m p e r a t u r e r e q u i r e m e n t s . However, f o r optimum r e s u l t s , s p e c i a l p r e s -
s u r e devices and curing methods as d e s c r i b e d in section 1 6 . 5 . 2 . 2 , 5 should
be used. The length of the o v e r l a p to the thickness of t h e skin should b e
approximately 125 to 1 , but s h o r t e r o v e r l a p s can be u s e d in r e p a i r s in which
the skins a r e not highly s t r e s s e d .
(3) A s t e p type of facing patch (fig. 16-11) having aerodynamic smooth-

n e s s , but with which only 50 p e r c e n t of the original tensile s t r e n g t h of the
facing can be developed. The step-type patch i s bonded in place, a f t e r the
c o r e h a s been replaced, by methods s i m i l a r to the o v e r l a p skin patch.
However, because i t i s n o r m a l l y u s e d in a r e a s having high aerodynamic
smoothness r e q u i r e m e n t s and aerodynamic heating , h e a t - r e s i s t a n t adhesives
a r e frequently employed. F o r m a x i m u m efficiency, t h e s e adhesives r e q u i r e
high c u r e t e m p e r a t u r e s and p r e s s u r e s s u c h a s can b e attained by vacuum
box a s s e m b l y , a s d e s c r i b e d in section 16. 5 . 2 . 2 . 5.
(4) A s c a r f - t y p e facing patch in which the m e t a l facing and facing plug

a r e both s c a r f e d . This i s a combination of the o v e r l a p and s t e p types of
skin r e p a i r s , i n which b e t t e r aerodynamic smoothness can b e obtained than
with t h e o v e r l a p patch, and higher s t r e n g t h efficiency than with the s t e p
patch. This type of r e p a i r , however, r e q u i r e s the u s e of tools and techni-
ques capable of a c c u r a t e l y machining long s c a r f s on e x t r e m e l y thin facings.
(5) An o v e r l a p type of r e s i n - g l a s s f a b r i c facing patch (fig. 16-12),

which h a s f a i r aerodynamic s m o o t h n e s s , is e a s y to f a b r i c a t e in the field with
a m i n i m u m of equipment and fits e a s i l y to t r a n s i t i o n c u r v a t u r e s in skin
s u r f a c e s . An o v e r l a p type of g l a s s - f a b r i c skin patch is f a b r i c a t e d by i m p r e g -
nating g l a s s cloth d i s k s with epoxy laminating r e s i n . T h e s e disks a r e then
1
laid over the r e p l a c e d c o r e and on the clean s k i n s u r f a c e as indicated i n the
figure. The s k i n a r e a should be t r e a t e d f o r adhesive bonding a s d e s c r i b e d
in section 16.5.2.2.3. E a c h individual r e s i n - i m p r e g n a t e d disk i s worked
into place using a squeegee blade, and the final ply i s c o v e r e d with r e s i n
and polyvinyl a c e t a t e film before final working out of the entrapped a i r . The
r e p a i r can be c u r e d without additional p r e s s u r e at r o o m t e m p e r a t u r e s , o r a t
elevated t e m p e r a t u r e s by the u s e of a h e a t blanket, hot sandbags, o r h e a t
lamp.
16-19
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- -~
MIL-HDBK-23A CHG N O T I C E 3 9999770 0348238 T b 9
16.5.2.2.5 Application of Curing P r e s s u r e and T e m p e r a t u r e . - - S e v e r a l

methods a r e employed f o r the application of c u r i n g p r e s s u r e and t e m p e r a -
t u r e to t h e adhesive u s e d in bonding r e p a i r patches:
(1) In the filling of t h e c o r e cavity with e p o x y - r e s i n f i l l m a t e r i a l s , bond-

ing c o r e s into place with e p o x y - r e s i n a d h e s i v e s , o r i3 t h e u s e of epoxy-
r e s i n g l a s s -cloth r e p a i r p a t c h e s , m o d e r a t e p r e s s u r e s are often u s e d . T h e s e
methods c o n s i s t of working out air bubbles using rod o r s p a t u l a and then
retaining the r e p l a c e m e n t with tape o r film a c r o s s the r e p a i r a r e a , o r the
u s e of fitted m e t a l blocks a n d l e a d o r s a n d weights to apply p r e s s u r e . T h e s e
types of r e p a i r s a r e frequently c u r e d at n o r m a l r o o m conditions, but in s o m e
i n s t a n c e s , additional h e a t is applied by t h e u s e of h e a t l a m p s , hot s a n d b a g s ,
o r h e a t blankets.
(2) P r e s s u r e r e q u i r e d f o r bonding patches t o facings with epoxy adhe-

s i v e s can b e obtained by m e c h a n i c a l m e a n s . On the t r a i l i n g edge r e p a i r of
sandwich p a r t s , conventional hand c l a m p s c a n b e u s e d in combination with
t h e n e c e s s a r y wedges and soft cushion m a t e r i a l s f o r even d i s t r i b u t i o n of
p r e s s u r e . F o r s o m e r e p a i r s , c h e r r y blind r i v e t s a r e u s e d f o r application
of adhesive bonding p r e s s u r e . F o r l e s s c r i t i c a l a r e a s on t r a i l i n g edge p a r t s ,
through r i v e t s a r e u s e d i n combination with m i c a r t a p l a s t i c doublers t o with-
s t a n d the riveting p r e s s u r e .
A s u g g e s t e d method of r e p a i r using self-tapping s c r e w s , a plywood

p r e s s u r e plate, and a cushion m a t e r i a l f o r applying p r e s s u r e is shown in
f i g u r e 16-13.
(3) A flexible t h e r m o s t a t i c a l l y controlled e l e c t r i c h e a t blanket and

vinyl vacuum bag is a convenient method i f e l e c t r i c and vacuum s o u r c e s a r e
available f o r applying heat and p r e s s u r e to c u r e a s u r f a c e s k i n patch bonded
with e p o x y - r e s i n a d h e s i v e s . F i g u r e 16- 14 i l l u s t r a t e s a method of bonding
a s u r f a c e patch using a vacuum gage and e l e c t r i c heating blanket.
When using the vacuum blanket r e p a i r technique

with a flexible heating pad, e x t r e m e caution
should be e x e r c i s e d t o s e e that t h e blanket seal
is tight and that the patch plate fits exactly t o
the contour of t h e sandwich. A leaky s e a l and a
poorly fitted patch plate c a n r e s u l t in no p r e s -
s u r e on t h e bond.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
16-20

L
____________- - --___-
MIL-HDBK-23A CHG N O T I C E 3 W 9997970 0 1 4 8 2 3 9 9 T 5 =

P
F i g u r e 16-15 shows the u s e of rigid heating blocks instead of the flexible
h e a t blankets f o r applying the curing t e m p e r a t u r e in combination with a
vacuum bag to apply p r e s s u r e . By the u s e of rigid h e a t blocks l a r g e r than
their contact s u r f a c e with t h e m e t a l skin patch, bonding p r e s s u r e s g r e a t e r
than n o r m a l vacuum p r e s s u r e c a n b e obtained. The s a m e g e n e r a l principle
has been u s e d in the design (fig. 16-16) of a rigid vacuum box and h e a t e r
block attached through a flexible g a s k e t to the sandwich panel.
The design and u s e of t h e s e vacuum bag o r box

devices in combination with rigid head blocks
should be carefully controlled by technical
p e r s o n n e l s o t h a t the p r e s s u r e s obtained on the
a r e a s do not c a u s e f a i l u r e of the sandwich panel.
(4) In addition to the t h e r m o s t a t i c a l l y controlled flexible heat blankets

and rigid h e a t blocks, i n f r a r e d heat l a m p s o r hot sandbags can b e used to
complete the c u r e of the adhesive bond in c e r t a i n types of bonded r e p a i r s .
The h e a t l a m p s should be rigidly stationed ( f i g . 16-17) a t a reasonable

d i s t a n c e f r o m the r e p a i r a r e a . A shielded thermocouple should be used to
indicate the t e m p e r a t u r e , and the t e m p e r a t u r e should be closely monitored
by moving the l a m p n e a r e r o r away f r o m the r e p a i r s o that the t e m p e r a t u r e
does not r i s e too rapidly, and S O that a constant curing t e m p e r a t u r e i s
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
obtained.
Heated sandbags can a l s o be u s e d to apply both p r e s s u r e and curing t e m -

p e r a t u r e t o the adhesive bonds on horizontal s u r f a c e s . The heated sandbags
will generally apply heat m o r e uniformly o v e r the e n t i r e r e p a i r a r e a than
can b e obtained with heat l a m p s .
E x c e s s i v e t e m p e r a t u r e concentration o r too rapid t e m p e r a t u r e r i s e by

any heating method c a n c a u s e f a i l u r e i n , t h e surrounding a r e a s of c e r t a i n
types of bonded construction,
16-21

~
MIL-HDBK-23A CHG N O T I C E 3 9999970 0148240 b17 M
Damages that extend completely through the c o r e and both facings of the
sandwich panel m a y b e r e p a i r e d by the s a m e g e n e r a l techniques as u s e d for
c l a s s 2 r e p a i r s but t h e r e m u s t be a c c e s s available to both facings of the
panel, the panel m u s t b e removed, o r s p e c i a l techniques m u s t be u s e d to
apply p r e s s u r e in bonding t h e i n n e r facing patch in place.
1 6 . 5 . 2 . 3 . 1 A c c e s s Available to Both Facings. --When a c c e s s i s avail-

able to both facings of the sandwich panel, the damaged a r e a can be removed
and a r e p a i r m a d e following the g e n e r a l techniques l i s t e d in section 16.5.2.2.
The inner facing patch is first bonded in place, c o r e r e p l a c e d , and then the
top facing patch bonded. In c e r t a i n a r e a s , s u c h a s t r a i l i n g e d g e s , it is pos -
sible to f i r s t replace the c o r e , and then simultaneously bond both facing
patches on using m e c h a n i c a l o r vacuum p r e s s u r e .
Sandwich panels with c l a s s 3 damage can a l s o be r e p a i r e d with a s a n d -

wich patch f a b r i c a t e d (fig. 16-10E) f r o m a s e c t i o n of sandwich panel having
the s a m e construction and c u r v a t u r e as the original panel. P r e s s u r e need
be applied only to the outer facing b e c a u s e , i n a p r o p e r l y f i t patch, this
p r e s s u r e w i l l b e d i s t r i b u t e d to the bonding s u r f a c e of the i n n e r facing. Heat
r e q u i r e d f o r the adhesive, however, should be applied to both s u r f a c e s .
This patch c a n a l s o b e f a b r i c a t e d with the o v e r l a p facing on the i n n e r facing
of the sandwich panel, an'd the r e p a i r hole in the outer facing filled with a
butt-type f l u s h facing patch, a f t e r the sandwich patch has been bonded i n
place, to r e s u l t i n an aerodynamically smooth o u t e r s u r f a c e . C a r e m u s t be
taken, possibly by bonding a doubler to the i n n e r f a c e , t o prevent peeling of
the unsupported i n n e r facing during the application of p r e s s u r e to the s a n d -
wich patch.
16.5.2.3.2 A c c e s s Not Available t o Both Facings. --When a c c e s s is not

available to the inner facing of a sandwich panel, the following p r o c e d u r e is
suggested:
(1) Remove the damaged facings and c o r e in the f o r m of a r e c t a n g u l a r

a r e a u s i n g the g e n e r a l methods d e s c r i b e d i n section 16. 5.2.2. 1.
(2) F a b r i c a t e backing plate and d r i l l n e c e s s a r y holes in plate and s a n d -

wich panel (fig. 16-18) f o r self-tapping s c r e w s to b e u s e d in applying
pressure.
( 3 ) Clean the s u r f a c e of the backing plate and the a r e a around the cutout
on the back of the r e p a i r .
16-22
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

=
.-
(4) Apply adhesive to the backing plate and position i n place on the inner
facing of the sandwich p a r t .
(5) F a b r i c a t e r e p l a c e m e n t c o r e patch and place in the c o r e cavity over

the backing plate.
(6) Apply cellophane s h e e t , plywood caul, and self-tapping s c r e w s a s

shown i n s t e p 1 of figure 16-18.
(7) After the adhesive has c u r e d , the s c r e w s and caul c a n be removed

and the s c r e w holes filled with a viscous m i x t u r e of epoxy r e s i n .
(8) T h e upper o v e r l a p facing is then bonded in place using s c r e w p r e s -

s u r e o r by the u s e of p r e s s u r e methods listed in section 16.5.2.2. 5.
An a l t e r n a t e p r o c e d u r e i s the u s e of a r e p l a c e m e n t sandwich patch with

p r e s s u r e being distributed to both facings simultaneously wvhen p r e s s u r e i s
applied to the f a c e of the patch using methods outlined in section 1 6 . 5 . 2 . 2 . 5.
Heat f o r curing the adhesive can be applied to the o u t e r bond line by the
u s e of h e a t blankets, hot sandbags, o r heat l a m p s , but it is difficult to
obtain h e a t on the i n n e r bond line and t h e r e f o r e adhesives should be u s e d
t h e r e that c u r e adequately a t r o o m conditions.
16.6 REPAIR O F BRAZED OR WELDED SANDWICH
Detailed r e p a i r p r o c e d u r e s a r e not available in published specifications

o r s t a n d a r d s . The following g e n e r a l p r o c e d u r e s coupled with p r o p e r choice
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
of m a t e r i a l s can m e r e l y s e r v e a s a c r u d e guide.
R e p a i r s c a n be accomplished by filling s u p e r f i c i a l dents and light damage

- with compounds such as silicone r u b b e r o r injecting adhesives o r potting
compounds. S m a l l holes can be r e p a i r e d by b r a z i n g on patch plates.
S e v e r e l y damaged a r e a s cannot be r e p a i r e d f o r continued s e r v i c e of the
p a r t and a t t e m p t s to m a k e r e p a i r s should only b e undertaken in e m e r g e n c y
a f t e r which the d a m a g e d p a r t should be r e p l a c e d a s soon as possible.
16, 6.1 Adhesive Injection R e p a i r s
Clean the s u r f a c e to be d r i l l e d with MEK (methyl-ethyl-ketone) o r

acetone. Wipe area d r y with a clean cheesecloth.
16-23
____ ~ _ _
f
MIL-HDBK-23A C H G N O T I C E 3 m 9999970 0 1 4 8 2 4 2 4 9 T m
Outline the void a r e a using a g r e a s e pencil o r felt point pen.
CAUTION: Do not u s e carbon l e a d pencils to outline void a r e a s o r m a r k

hole p a t t e r n s .
Lay out an injection hole p a t t e r n within the outlined void a r e a o r dented

a r e a . The distance between adjacent holes in the p a t t e r n s h a l l be f r o m 1 . O
to 1 . 5 inches. The hole p a t t e r n s h a l l extend to within O. 50 inch of the void
p e r i m e t e r outline. F o r dents 1. O inch o r l e s s in d i a m e t e r , one hole s h a l l
be d r i l l e d in the approximate c e n t e r of the dent. F o r dents o v e r 1. O inch to
. 1 - 1 / 2 inches in d i a m e t e r the distance between adjacent holes in the p a t t e r n
s h a l l be approximately 1 . 0 inch. R e f e r to figure 16-19.
Using a O . 125-inch-diameter d r i l l with a d r i l l s t o p attached, d r i l l hole

pattern. F o r c o r e to facing and v e r t i c a l t i e void a r e a s d r i l l holes to a depth
of O. 10 inch. F o r c o r e to facing void a r e a s adjacent to a n edge m e m b e r
vertical wall, d r i l l holes in v e r t i c a l wall to a depth of 1. O inch.
CAUTION: Do not u s e a c e n t e r punch to s t a r t d r i l l . Do not apply

e x c e s s i v e p r e s s u r e to facing o r edge m e m b e r when drilling.
Tape a thermocouple c l o s e to the r e p a i r a r e a and d r y panel at 2 5 0 " F

f o r 3 0 m i n u t e s . Do not tape o v e r injection holes.
Remove thermocouple and tape. Inject five to eight shots of adhesive

into e a c h hole using a l e v e r gun as shown i n figure 16-20.
CAUTION: Do not apply p r e s s u r e t o facing or edge m e m b e r with l e v e r

gun.
R e m o v e adhesive f r o m a r e a surrounding injection holes using clean

cheesecloth moistened with M E K o r acetone. Wipe a r e a d r y with a clean
cheesecloth.
CAUTION: Do not allow flow of solvent into injected holes.
Apply one l a y e r of polyester tape o r equivalent o v e r injected a r e a .
CAUTION: Do not t r i m tape on panel.
16-24
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 6 9 9 9 9 9 7 0 O348243 326 9
Open e a c h injection hole in l a y e r of tape using a blunt punch.

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I n s e r t a thermocouple into a n opened injection holc approsimatvly

1 / 8 inch deep.
NOTE: When m o r e than one injected a r c a is on any one s u r f a c e , a

m i n i m u m of one thermocouple s h a l l be u s e d f o r e a c h injected
area.
Apply a second l a y e r of p o l y e s t e r tape o r equivalent o v e r injected a r e a

and thermocouple lead.
CAUTION: Do not t r i m tape on panel.
Apply a film of r e l e a s e compound t o tape and l o c a l a r e a surrounding

tape.
C u r e injected adhesive with void or dented s u r f a c e down. using a n ovcn

i n which the t e m p e r a t u r e can be controlled t o within * l o " F.
Allow a s s e m b l y to cool t o r o o m t e m p e r a t u r e .
Remove thermocouple and t a p e f r o m injected a r e a .
Clean s u r f a c e s of any e x c e s s adhesive.
CAUTION: In removing e x c e s s adhesive d o not damage the thin f a c i n g s .

A lightweight i n s t r u m e n t having beveled edges Lvith no s h a r p
c o r n e r s should be u s e d i n the cleaning o p e r a t i o n . Wipe the
injected a r e a with acetone o r M E K to r e m o v e s u r f a c e film
c a u s e d f r o m polyester t a p e and r e l e a s e compound.
R e d r i 1 injection holes to a depth of O. 12 inch using a O . 125-inch-

d i a m e t e r d r i l l with a d r i l l s t o p attached. When a n inspection plug hole h a s
b e e n u s e d as an injection h o l e , r e d r i l l the hole t o a de.pth of O . 1 2 inch using
a 5 / 16-inch-diameter d r i l l with a d r i l l s t o p attached.
Seal injection holes and complete dent r e p a i r according t o p a r a g r a p h

16. 6.2.
16-25

16. 6 . 2 Potting R e p a i r s
Wipe the d i s c r e p a n t a r e a and the surrounding a r e a with c l e a n cheesecloth

m o i s t e n e d with MEK.
Sand the d i s c r e p a n t a r e a v e r y lightly using aluminum oxide p a p e r .
F l u s h the a r e a thoroughly with c l e a n trichloroethylene.
Blow the s u r f a c e d r y with c l e a n d r y a i r .
Wipe the d i s c r e p a n t a r e a thoroughly with clean cheesecloth moistened

with acetone.
.
M a s k off around the cleaned a r e a with polyester tape o r equivalent and
allow the a r e a to air d r y f o r 30 m i n u t e s .
Fill the d i s c r e p a n t a r e a with potting compound and smooth to contour

with s t r a i g h t e d g e o r soft b r i s t l e b r u s h moistened with solvent before the
compound vulcanizes.
C u r e a t r o o m t e m p e r a t u r e f o r 24 h o u r s .
16. 6 . 3 B r a z e d P a t c h Repair
This type r e p a i r s h a l l be u s e d on b r a z e d honeycomb panel c o r e to facing

a r e a s which have been damaged by dents o r punctures. A puncture i s
defined a s a hole o r c r a c k through one facing only,
1 6 . 6 . 3 . 1 P r e p a r a t i o n of Damaged A r e a
P r i o r to Brazing
(1) Clean v e r y thoroughly a t l e a s t 12- by 12-inch a r e a of facing (dam-

aged a r e a in approximate c e n t e r ) with trichloroethylene. Wipe the s u r f a c e
with a c l e a n cheesecloth ( o r equivalent) which h a s been moistened with the
solvent and follow immediately with a clean d r y cloth. A l l e x c e s s t r i c h l o r o -
ethylene s h a l l be wrung f r o m the cleaning cloth p r i o r to wiping o v e r the
damaged facing.
CAUTION: S t o r e trichloroethylene in a clean m e t a l c o n t a i n e r . Do not

dip cleaning cloth into solvent. P o u r solvent onto cloth.
16-26
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9999970 OLYB2Y5 L T 9 =
(2) D e t e r m i n e the s i z e of the damaged a r e a . T h e damaged a r e a , by
definition, will include the following:
(a) The dent, including the extent of any core-to-facing delamination,

or
(b) T h e hole o r c r a c k s including the extent of the accompanying dented
a r e a around the puncture and, in addition, any core-to-facing
delamination. The a r e a adjacent to the dent o r the puncture s h a l l be
checked for c o r e -to-facing delamination by tapping the facing lightly
with a light blunt i n s t r u m e n t o r m e t a l d i s k s u c h as a coin.
(3) Buff the a r e a to be r e p a i r e d lightly with No. 120g aluminum oxide

p a p e r until a uniform s u r f a c e appearance i 5 obtained.
(4) C r a c k s only: S t o p - d r i l l each end of the c r a c k using a No. 30

( O , 1285-inch-diameter) d r i l l . U s e a p p r o p r i a t e methods t o d e t e r m i n e the
extent of the c r a c k p r i o r to s t o p d r i l l i n g ,
CAUTION: Use d r i l l s t o p to prevent drilling into opposite facing.
F o r r e p a i r s requiring facing removal a c c o m p l i s h the following (in addi-

tion to the s t e p s outlined above):
(1) Outline the damaged a r e a using a g r e a s e pencil o r felt point pen.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
CAUTION: Do not u s e carbon lead pencils.
(2) M e a s u r e the l a r g e s t dimension of the damaged a r e a . T h i s dimen-

sion s h a l l be the d i a m e t e r of the c i r c u l a r cut-out in the damaged facing.
Make a 6- by 6-inch t e m p l a t e , O. 020 to O . 040 inch thick, with a c i r c u l a r cut-
out the s a m e d i a m e t e r as the damaged facing section to be removed. F o r m
t e m p l a t e , if n e c e s s a r y , t o s a m e contour a s a r e a surrounding damage.
(3) . U s i n g the t e m p l a t e as a guide cut completely through the d a m a g e d

facing with a sharp-pointed i n s t r u m e n t s u c h a s a s c r i b e . R e f e r to f i g u r e 1 6 - 2 1
(4) P r y u p edge of damaged facing using a s m a l l s c r e w d r i v e r ( o r equiv-

a l e n t ) . P l i e r s m a y then be u s e d t o peel off facing cut-out.
CAUTION: U s e e x t r e m e c a r e when removing facing cut-out s o a s not to

d a m a g e the c o r e o r panel f u r t h e r .
(5) Smooth edge of opening in facing to r e m o v e a l l nicks and b u r r s .

F i l e s m o o t h and uniform a s required.
16-27

r ~-
(6) Straighten damaged and bent c o r e c e l l walls to bring edges back to

t h e i r o r i g i n a l s u r f a c e (inside s u r f a c e of damaged facing). If the c o r e c e l l
walls a r e damaged extensively and cannot be r e s t o r e d to t h e i r original s u r -
--
f a c e , o r i f facing being r e p a i r e d exceeds O. 008 inch thick, accomplish the

following :
(a) N e s t inside o r i g i n a l c o r e c e l l s foil ribbons o r s t r i p s of p r o p e r alloy

and t h i c k n e s s . R e s t o r e r e p l a c e m e n t c o r e to o r i g i n a l c o r e c e l l s i z e
and configuration as n e a r a s possible. R e f e r to figure 16-22,
NOTE: Clean s t r i p s with trichloroethylene before putting in place.
('a) Tack-weld c o r e r e p l a c e m e n t s t r i p s to remaining original c o r e c e l l s

and to e a c h o t h e r . Refer to f i g u r e 16-23.
CAUTION: Do not burn through foil ribbons.
NOTE: It is not n e c e s s a r y f o r c o r e r e p l a c e m e n t s t r i p s to extend to

opposite facing. It will be p e r m i s s i b l e to bring the s u r f a c e
of the r e p l a c e m e n t c o r e c e l l wall edges u p to the s a m e con-
t o u r a s the outside of the damaged facing but not beyond.
Use No. 120g e m e r y cloth and sanding block to sand c o r e
down to contour.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(7) D r i l l a N o . 3 0 ( O . 1285-inch-diameter) hole in the facing opposite

the r e p a i r a r e a . The hole s h a l l be d r i l l e d in the c e n t e r of the c e l l which i s
c l o s e s t to the c e n t e r of the facing cut-out.
1 6 . 6. 3 . 2 P r e p a r a t i o n of Auxiliary Equipment
P r i o r to Brazing
(1) F a b r i c a t e a graphite h e a t e r block O . 5 to 1. O inch t h i c k , with a b a s e

d i a m e t e r O . 12 inch l a r g e r than the e x t e r n a l patch d i a m e t e r . Contour the
g r a p h i t e block t o the panel by rubbing the block on a s h e e t of N o . 120g e m e r y
cloth laid on the panel adjacent to the r e p a i r a r e a . When contouring block
f o r nacelle panel r e p a i r aline c e n t e r l i n e of block with c e n t e r l i n e of a r e a to
b e r e p a i r e d and sand block p a r a l l e l to direction of l e a s t contour (longitudinal).
M a r k top s i d e of block s o it can be p r o p e r l y o r i e n t e d with r e p a i r a r e a when
placed on the c o v e r s h e e t .
NOTE: Contouring of g r a p h i t e block m u s t be accomplished with e x t r e m e

c a r e to i n s u r e full contact of e x t e r n a l patch with the facing and
c o r e in the a r e a of the r e p a i r .
16-28

---
MIL-HDBK-23A CHG NOTICE 3 9999970 0348247 T71
(2) M a k e two 6- by 6-inch chill plates f r o m O. 064-inch-thick copper

( C o m m e r c i a l g r a d e , soft annealed). F o r m chill plates to contour of panel
on facing a r e a d i r e c t l y opposite r e p a i r a r e a . D r i l l No. 3 0 hole in c e n t e r of
e a c h plate.
(3) Make a s q u a r e stop-off s c r e e n f r o m s t a i n l e s s s t e e l w i r e cloth ( N o .

100 s q u a r e m e s h , plain weave-wire s i z e O . 0 0 3 - i n c h - d i a m e t e r m a t e r i a l ) .
The s c r e e n s h a l l be 1 . 0 inch l a r g e r than the d i a m e t e r of the cxternal patch.
(4) Make a n 8 - by 8-inch c o v e r s h e e t f r o m O . 005-inch-thick s t a i n l e s s

steel,
1
16. 6 . 3 . 3 P r e p a r a t i o n of P a t c h P l a t e and
R e p a i r Alloy
( i ) F a b r i c a t e the patch f r o m the facing alloy a t the p r o p e r heat t r e a t -

m e n t and t h i c k n e s s , If the thickness of the e x t e r n a l patch is 0.016 inch o r
g r e a t e r , the edge of patch s h a l l be c h a m f e r e d a t a 5 : l r a t i o . The edge of
t h e patch s h a l l b e f r e e f r o m nicks and b u r r s . F i l e smooth and uniform as
r e qui r e d.
( 2 ) Cut r e p a i r alloy d i s k s t h e s a m e d i a m e t e r as the opening i n the fat-

ing. Cut o r s l i c e t h e alloy d i s k s i n the m a n n e r i l l u s t r a t e d by f i g u r e 16-4.
NOTE: T h i s s t e p not r e q u i r e d f o r patch r e p a i r of dents and s t o p - d r i l l e d

cracks.
( 3 ) Cut one (1) r e p a i r alloy disk O . 12 ( * 0 . 0 3 ) inch l a r g e r in d i a m e t e r

than the d i a m e t e r of the e x t e r n a l patch. Cut o r s l i c e alloy disk in the m a n -
n e r i l l u s t r a t e d by f i g u r e 16-24.
(4) F o r d e n t s , c u t s e v e r a l s m a l l s l i v e r s o r s t r i p s of r e p a i r alloy
approximately 1 / 1 6 inch wide t o be u s e d f o r filling d e p r e s s i o n i n skin.
16. 6 . 3 . 4 Cleaning P r o c e d u r e s f o r R e p a i r
M a t e r i a l s and R e p a i r Alloy
(1) Buff patch with N o . 3 2 0 e m e r y cloth ( o r equivalent) until a uniform

s u r f a c e a p p e a r a n c e is obtained.
( 2 ) Clean t h e p a t c h , r e p a i r a l l o y , w i r e cloth, and c o v e r s h e e t v e r y

tho roughly with trichloroethylene .
16-29
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_____ ~- -_
MIL-HDBK-23A CHG N O T I C E 3 W 9999970 0348248 908 W
.
c
NOTE: U s e clean r u b b e r gloves o r c l e a n white l i n t l e s s cotton gloves to
handle cleaned r e p a i r m a t e r i a l s . Keep cleaned r e p a i r m a t e r i a l s
i n c l e a n wrapping p a p e r o r cheesecloth until r e a d y t o place i n
position o v e r r e p a i r a r e a .
( 3 ) Clean the a r e a t o b e r e p a i r e d i n t h e following m a n n e r :
(a) F o r dents s c r u b t h e patch o v e r l a p a r e a and 6 inches beyond v e r y

thoroughly with c l e a n c h e e s e c l o t h which h a s b e e n m o i s t e n e d with
phosphoric acid cleaner.:: Wipe t h e a r e a cleaned with the a c i d
s e v e r a l t i m e s with clean cheesecloth which has b e e n moistened with
d i s t i l l e d tsate r .
CAUTION: Do not wipe p a s t t h e p e r i m e t e r of t h e a c i d cleaned a r e a when

removing acid with d i s t i l l e d w a t e r . Do not touch cleaned
a r e a with b z r e hands.
(b) F o r punctures ( s t o p - d r i l l e d c r a c k s and damage requiring facing

removal) s c r u b the patch o v e r l a p a r e a and s i x (6) inches beyond v e r y
thoroughly with c l e a n c h e e s e c l o t h which h a s been m o i s t e n e d with
phosphoric acid c l e a n e r . :k All excess acid c l e a n e r s h a l l b e wrung
f r o m the cleaning cloth p r i o r t o rubbing o v e r the patch o v e r l a p a r e a .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
__
CAUTION: Use e v e r y precaution t o prevent the phosphoric acid c l e a n e r
f r o m entering the c o r e a r e a of the panel.
If any acid c l e a n e r e n t e r s the c o r e a r e a , t u r n the panel o v e r s o that

t h e r e p a i r a r e a is down and f l u s h the opening(s) in the panel s e v e r a l
times with a d i s t i l l e d w a t e r s p r a y . Allow e x c e s s \Vater to d r i p out,
then t u r n panel o v e r . P l a c e a thermocouple l e a d in the approximate
c e n t e r of the r e p a i r a r e a and d r y t h e panel at 250 F f o r 3 0 minutes
with h e a t l a m p s .
If no acid c l e a n e r e n t e r s t h e c o r e a r e a , wipe t h e cleaned a r e a

s e v e r a l times with c l e a n cheesecloth which h a s b e e n moistened Lvith
d i s t i l l e d ~ < a t e r .A l l e x c e s s w a t e r s h a l l be wrung f r o m the cleaning
cloth p r i o r to wiping o v e r the cleaned a r e a .
CAUTION: Do not wipe p a s t the p e r i m e t e r of t h e acid-cleaned a r e a when

removing a c i d with d i s t i l l e d w a t e r . Do not touch t h e cleaned
a r e a with b a r e hands,
::Cleaner composition, by weight: 1270 phosphoric a c i d (8570 N . F. o r b e t t e r ) ;

16% c i t r i c a c i d (USP); 870 synthetic soap; 1270 MEK; 5270 d i s t i l l e d w a t e r .
16-30

MIL-HDBK-23A CHG N O T I C E 3 9999970 0 3 4 8 2 4 9 8 4 4 =
16.6.3.5 Lay-Up and Brazing of R e p a i r A r e a
DraLv coordinate l i n e s on facing to locate the c e n t e r of the a r e a to

(1)
b e r e p a i r e d using a g r e a s e pencil o r felt point pen s o t h a t the l i n e s v.-ill
extend p a s t the edges of t h e c o v e r s h e e t .
CAUTION: Do not d r a w lines through the a r e a cleaned Xvith phosphoric

acid. Do not u s e c a r b o n l e a d p e n c i l s .
(2) P l a c e small d i s k s of r e p a i r alloy o v e r c o r e in facing opening.
NOTE: This s t e p not r e q u i r e d f o r patch r e p a i r to dents o r s t o p - d r i l l e d

cracks.
CAUTION: Do not touch cleaned a r e a o r r e p a i r m a t e r i a l s with bare

hands. W e a r c l e a n r u b b e r gloves o r white l i n t l e s s cotton
gloves.
( 3 ) F o r dcnts fill d e p r e s s i o n i n facing with small s l i v e r s o r s t r i p s of
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
r e p a i r alloy.
(4) Tack-weld l a r g e d i s k of r e p a i r alloy t o patch. Allow even o v e r l a p

of alloy around c i r c u m f e r e n c e of patch.
(5) Tack-weld (two p l a c e s , s p a c e d 1 8 0 " a p a r t approximately i / 16 inch

in f r o m edge of patch) t h e patch and r e p a i r alloy to t h e panel s o t h a t the ceri-
t e r of t h e patch i s o v e r t h e c e n t e r of the a r e a to be r e p a i r e d .
(6) P l a c e thermocouple lead in position s o t h a t the fused .end-wire bead

is touching t h e edge of t h e alloy extending p a s t edge of e x t e r n a l patch. Aline
thermocouple lead and t a p e in position. U s e No. 3 0 gage c h r o m e l - a l u m e l o r
iron-constantan depending upon type of t e m p e r a t u r e r e c o r d e r available.
(7) Tack-weld (two places) s t a i n l e s s s t e e l w i r e cloth to edge of patch s o

t h a t w i r e cloth i s c e n t e r e d o v e r patch. R e f e r t o f i g u r e 16-25.
(8) P l a c e O. 005-inch-stainless s t e e l c o v e r s h e e t in position s o t h a t

c e n t e r of s h e e t is as c l o s e t o the c e n t e r of the r e p a i r a r e a as possible. Hold
c o v e r s h e e t t o contour of panel with hand p r e s s u r e and tape c o v e r s h e e t to
panel on one s i d e . M a r k coordinate l i n e s on c o v e r s h e e t .
( 9 ) I n s e r t a r g o n line ( O . 06-inch-minimum inside d i a m e t e r cooper t u b e ,

c o m m e r c i a l g r a d e ) under c o v e r s h e e t 1!8 inch t o 3 / 8 inch. T a p e argor, line
i n position a n d f i n i s h taping c o v e r s h e e t t o panel. R e f e r t o f i g u r e 16-25.
16-31

MIL-HDEK-23A CHG N O T I C E 3 9979970 OLLIB250 5bb
(10) I n s e r t a r g o n line (O. 06-inch-minimum inside d i a m e t e r copper tube,

c o m m e r c i a l g r a d e ) through holes in chill plates and then through hole i n f a c -
ing opposite r e p a i r a r e a . Tube s h a l l extend p a s t facing inside panel approxi-
m a t e l y 1/ 8 inch to 1/ 4 inch.
(11) P l a c e chill plates and chill plate support r a c k in position next to

facing opposite c e n t e r of r e p a i r a r e a . Apply vacuum ( 2 0 inches H g m i n i m u m )
t o chill plate support r a c k vacuum cups using venturi and c o m p r e s s e d a i r o r
by using vacuum pump.
(12) Attach a r g o n lines to s t o r a g e cylinder and s t a r t argon purge. F o r

purge of r e p a i r area u n d e r cover s h e e t s e t flow rate a t 20 ( I l ) cubic feet p e r
h o u r . When r e q u i r e d , flow rate f o r purging of panel i n t e r i o r s h a l l b e 5 ( I l )
cubic f e e t p e r hour. P u r g e f o r a m i n i m u m of 2 0 minutes.
. NOTE: F o r e a c h b r a z e d patch r e p a i r , argon dew point t e m p e r a t u r e s h a l l

be -80" F o r lower.
(13) Adjust oxygen ( c o m m e r c i a l g r a d e , welding) and acetylene ( c o m m e r -

c i a l g r a d e ) flow valves on b r a z i n g t o r c h to i n s u r e c o r r e c t s i z e and intensity
of flame. After c o r r e c t adjustments have been m a d e , f l a m e c a n be cut off.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
(14) C e n t e r g r a p h i t e block on patch. U s e coordinate lines to aline
g r a p h i t e block. U s e e x t r e m e c a r e to i n s u r e that g r a p h i t e block is i n p r o p e r
position. P l a c e g r a p h i t e block s u p p o r t cup in position on block and apply
30 ( i 5 ) p s i t o s u p p o r t cup through p r e s s u r e rods. When a m i n i m u m of
20 m i n u t e s ' t i m e h a s e l a p s e d s i n c e start of purging, reduce a r g o n flow to
r e p a i r a r e a u n d e r cover s h e e t to 5(*1) cubic feet p e r hour. When panel
i n t e r i o r purging is r e q u i r e d , reduce flow rate to Z(I1) cubic f e e t p e r hour.
(15) Apply h e a t to r e p a i r a r e a through graphite block at s u c h a rate that

a thermocouple t e m p e r a t u r e is r e a c h e d f o r the p r o p e r t i m e to b r a z e the
repair.
CAUTION: U s e F i b e r f r a x blanket to c o v e r top of c o v e r s h e e t and to

p r o t e c t b r a z i n g tool.
(16) R e c o r d t i m e - t e m p e r a t u r e cycle and o t h e r pertinent panel d a t a on

h i s t o r y sheet. R e c o r d t e m p e r a t u r e at 1-minute i n t e r v a l s .
(17) Allow r e p a i r a r e a t o cool p r o p e r l y . Maintain p r e s s u r e on r e p a i r

area. Do not f o r c e air cool r e p a i r a r e a , but continue a r g o n flow at 5(*1)
cubic f e e t p e r hour.
(18) Inspect both s i d e s of panel in r e p a i r a r e a to d e t e r m i n e conformance

t o contour r e q u i r e m e n t s .
16-32
---------

R E F E R E N C E D DOCUMENTS

Current I n s t r u c t i o n s f o r R e p a i r of A i r c r a f t a n d W e a p n s S a n d n i c h
S t r u c t u r e s . P a r t I--All P l a s t i c Construction. Military
Standard M I L - S T D - 7 68(ASG).
(16-2) U . S . D E P A R T M E N T O F D E F E N S E
Current I n s t r u c t i o n s f o r R e p a i r of A i r c r a f t a n d W e a p o n s S a n d w i c h
Structures. Part I I - - M e t a l Construction. M i l i t a r y S t a n d a r d
M I L -S T D - 7 68(ASG) a
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
A d d i t i o n a l detailed i n f o r m a t i o n is a v a i l a b l e i n t h e f o l l o w i n g :
. (1) T. O. I F - 4 C - 3 - 1 T e c h n i c a l m a n u a l , s t r u c t u r a l r e p a i r i n s t r u c t i o n s ,
U . S . A . F., F - 4 C , F - 4 D , a n d R F - 4 C .
(2) T. O. 1F- 1 0 2 A - 3 - 1 T e c h n i c a l m a n u a l , s t r u c t u r a l r e p a i r s , U . S . A . F.
Series, F-102A and TF-102A.
( 3 ) T.O. 1 F - l O 6 A - 3 T e c h n i c a l m a n u a l , s t r u c t u r a l r e p a i r s , U . S . A , F.
Series, F-106A and F-106B.
(4) T.O. 1 B - 5 8 A - 3 Technical manual, s t r u c t u r a l r e p a i r i n s t r u c t i o n s , a i r -
craft and p o d s , U . S . A . F. S e r i e s , B 5 8 A , N B 5 8 A , T B 5 8 A , a n d
YB/RB-58A.
(5) ( U . S . A . F . ) T.O. - l F - l l l A - 3
( N a v y ) NAVAIR 0 1 - 1 O F A A - 3
T e c h n i c a l manual, s t r u c t u r a l r e p a i r i n s t r u c t i o n s , U . S. A. F. S e r i e s ,
F-11lA, Navy Series F - 1 l l B .
(6) T. O. 1 C - M A - 3 T e c h n i c a l m a n u a l , s t r u c t u r a l r e p a i r i n s t r u c t i o n s ,
USAF Series, 141A, A i r c r a f t .
(7) T. O. I C - 5 A - 3 Technical m a n u a l , s t r u c t u r a l r e p a i r i n s t r u c t i o n s ,
U S A F Series, 5A, A i r c r a f t .
1 C-33
____c_c_-
.- -
-_____-
----
y--
I-
,DAMAGE TO fAC/NG
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
d r - / O O d y / DAMAGED MA TERIAL
I REMOVED BY SANDING
REPACED LAMINA TIONS

/ SANDED TO courom
M 92868 F
F i g u r e 16-1. --Steps in r e p a i r of 'class 1 d a m a g e s to sandwich facings.
------

___- -- -
NIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 3 4 8 2 5 3 275
,DAMAG TO FACING AND CORE
PA TCH
/ WE T L AMINA TED PA TCH
'COR. RF ACED
?I '32 867
Figure 16-2. --Steps in the r e p a i r of class 2 damages.
---
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

NIL-HBBK-23A CHG N O T I C E 3 m 9999970 0148254 L O L
,HOL E THROUGH SANDWICH
I
I
I
HOL E TRfMMED, CORE REMO E D ,

/ AND FACING SCARFED
,WE T-L AMINA TED PA TCff
COMPLE TE E Y SCARFING AND WE T -L AIMINA TING OPPOSITE

FACING IN A SIMILAR OPERATION
M 135 309
Figure 1 6 - 3 . --Steps in the s c a r f e d type of r e p a i r to c l a s s 3 d a m a g e s ,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

.-
,HOL E THROUGH SANDW/CH
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
HOL E TU/MMED, CORE RMO E D ,
AND FAC/NG 3TEP -PEEL ED I
TEMPORARY BLOCK TEMPORAR Y SHIM

I
ou MOLD CORE RPL ACED
COMPLETE B Y STEP-PEEL /NG AND WE T-LAM/NATING OPPOS/T
FACING /N A S/M/LAR OPERAT/ON
Pi 135 310
F i g u r e 1 6 - 4 . --Details of stepped-joint method of r e p a i r of c l a s s 3

damages.

-___ - ~-
MIL-HDBK-23A CHG N O T I C E 3 7779770 0148256 T 8 4
CEN TER COORDINA TES
ZM 1 1 3 2 7 6
Figure 16-5. - - T y p i c a l c l a s s 2 damage t o one facing and c o r e of s a n d -

w i c h panel.
._-__
--------
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

t __
flIL-HDBK-23A CHG N O T I C E 3 9 9 9 7 9 7 0 OLL18257 710
ZM 113 L77
CUTTING OUT DAMAGE
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 16-6. - - R e m o v a l of d a m a g e d a r e a from sandwich panel u s i n g

e l e c t r i c d r i l l , r o u t e r b i t , and t e m p l a t e .

ROUTER BIT
ROUTER ASSEMBLY
AIR CONTROL VAL VE
ADJUSTMENT
THREADS
ROUTER FACE
PLA TE AND GUIDE
ROUTER TEMPLA TE
W i14 641 ROUTER BIT
F i g u r e 16-7. --Removal of damaged a r e a f r o m sandwich panel using

pneumatic r o u t e r s , r o u t e r bit, and t e m p l a t e .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- ~ _ _ _ _ . _ - ~- __
MIL-HDBK-23A C H G N O T I C E 3 E 9999970 0348259 793
F i g u r e 16-8. --Step cut of facing surrounding c o r e cavity for u s e in

fabricating flush repair.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_-
flIL-HDBK-23A CHG N O T I C E 3 = 9977970 0348260 405 M
/ \
n ORIGINAL CORE TO SKIN ADHESIVE
. I I
u4 au
SECTION SHOiING UNDERCUT
V LFINISHED UNDERCUT AREA
F i g u r e 16-9. - - U s e of hand-operated cutting tool to u n d e r c u t c o r e

material.
- --
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- _ _ _ _ - -
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 O L 4 8 2 h L 341
VI
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F i g u r e 16-11. --Step-type s k i n patch f o r sandwich r e p a i r .

= 9999970 0348263 3 3 4 H
-
RESIN-G ASS
FABRIC iAMlffA TE
REP ACMENT
HOUEYCOMB CORE
\
SEC TION THROUGH REPA / R
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F i g u r e 16-12. - - O v e r l a p g l a s s - f a b r i c facing patch f o r sandwich repa,ir.

MIL-HDBK-23A CHG N O T I C E 3 9999970 0248264 050 M
,DAMAGE TO METAL FACfNG
HONEYCOMB CORE
,PL YWOOD PRESSURE PLATE
CEL
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P W C X B OR SELF-TAPPING SCRWS-+.!f
'i 92 871 E
F i g u r e 1'6-13, --Method of applying curing p r e s s u r e to single facing

patch (class 2 damage) using m e t a l self-tapping s c r e w s and cushioned
plywood plate.
.-

__
___
MIL-HDBK-23A
--
CHG N O T I C E 3 = 9999970 0148265 T97
PATCH PLATE
ROUGH L
IOMESIVE
VEM L I V E R
ff IDHESIVE
A Application of adhesive to surface of sandwich. 6 Piacing facing patch over repair area
VINYL SHEET THERMOC\UPLE LEAD HEAT .PAD THERMOC0,UPLE LEAD
TO H E A T
CONTROL UNIT
c Taping vinyl sheet and thermocouple in place over facing patch D Placing heat pad over repair area.
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CERFWITLD F L E X I B L E ELECTRIC WEITIUO PAD

.LEEDEI UOSE\
4 AICETATE TIPE
ZINC C H R O U A T E
SEbLlNG COMPOUND
I/.-IlUII
VICUUY WOSE
E Heat blanket is covered with glass fabric and vinyl

bacuum blanket is fastened over vacuum hose
M 135 218
F i g u r e 16- 14. --Bonding facing patch on a sandwich panel, using heating

blanket and vacuum bag.
Provided by IHS Y Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard

MIL-HDBK-23A CHG N O T I C E 3 9 9 7 9 9 7 0 0348266 9 2 3 W
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r HATR SWITCH THOroS E
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- /
-AND WICH
PANEL
/-COVER
A
VACUUM BOX
SALING GASK SALING GASKET
CU IA WA Y VIEW
VACUUM BOX ASSEMBLY
Il u4 6h.o
F i g u r e 16-16. --Vacuum box and r i g i d h e a t e r block u s e d for maintaining

t e m p e r a t u r e and p r e s s u r e during c u r e of adhesive-bonded r e p a i r patch.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 011182b8 7Tb
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 16-17. - - U s e of heat l a m p to complete c u r e of bonded r e p a i r .
------
------------

MIL-HDBK-23A C H G N O T I C E 3 m 9999970 OL48269 6 3 2 m
FILLED SCREW HOLES IN COVER PLATE

/(HOLES USED IN GLUING COVER PLATE)\
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THRo(KiH BffEL AND EACUING
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STEP I -
EACUING PL A TE +CELLOPHANE
AND CORE
BEING GLUED
IN PL ACE
STEP 2-
TAPERED COVER
PL A TE BEING
GLUED IN PLACE
TAPERED COVER PLA

ME THICUNESS AS
COMPLETED
REPAIR
SECTIONS THROUGH A -A SHOWING STEPS IN MAKfNG REPAIR
Figure 1 6 - 1 8 . --Method of repairing class 3 damage when panel i s

accessible from oniy one s i d e .
--_ -
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----__I----

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SECTION A-A
(Exaggerated For Clarity)
F i g u r e 1 6 - 2 0 . --Injection of adhesive w i t h l e v e r gun.
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~
9999970 0148272 127 =
24 135 211
F i g u r e 1 6 - 2 1. - -Preparation of sandwich facing for r e p a i r .
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F i g u r e 1 6 - 2 2 . - - R e p a i r of s a n d w i c h core.
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- ~ _ _ _ _ _ - -
MIL-HDBK-23A CHG N O T I C E 3 9999970 OLLI827Y T T T
TACK WELD MACHINE
TACK WELD
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H 135 213
F i g u r e 16-23. --Tack-welding sandwich c o r e .

___-
M-I L - H D B K - 2 3 A CHG N O T I C E 3 9999970 0 3 4 8 2 7 5 936
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F i g u r e 1 6 - 2 4 . - - P r e p a r a t i o n of b r a z e alloy d i s k s .

- ----- __ -- ____
9999970 0 3 4 8 2 7 6 8 7 2 =
MIL-HDBK-23A CHG NOTICE 3
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U 135 214
Figure 16-25. - - A r r a n g e m e n t of r e p a i r components.

I _-
MIL-HDBK-23A C H G N O T I C E 3 9999970 0348277 7 0 9
MIL-HDBK-23A
30 Dec 1968
CHAPTER 17
DURABILITY
17.1 GENERAL
An a c c e p t a b l e sandwich s t r u c t u r e , i n addition t o p o s s e s s i n g specified

i n i t i a l physical p r o p e r t i e s , m u s t be r e l a t i v e l y unaffected by continued expo-
s u r e t o conditions i m p o s e d by s e v e r e s e r v i c e . Obviously, with sandwich
combinations involving new and u n t r i e d m a t e r i a l s , it i s i m p o s s i b l e t o p r o -
vide t h e a s s u r a n c e of adequate s e r v i c e t e s t s , and r e l i a n c e m u s t t h e r e f o r e
by placed on t e s t s conducted a f t e r artificial aging u n d e r conditions thought
to bc typical of scvei-e s e r v i c e . Artificial-aging t e s t s a r e t i m e - c o n s u m i n g
and often do not include all t h e possible combinations of e x p o s u r e conditions
t h a t might b e encountered i n a c t u a l s e r v i c e .
17.1. 1 E n v i r o n m e n t a l ExDosure of
Adhesive -Bonded J o i n t s
Bonded lap-joint aluminum panels p r e p a r e d with v a r i o u s a d h e s i v e s have

been w e a t h e r e d f o r p e r i o d s u p t o 3 y e a r s in F a i r b a n k s , -4laska; State College,
N. Mex. ; Madison, W i s . ; and the P a n a m a Canal Zone ( r e f s , 17-1 and 17-2).
T h e e f f e c t s of t h e s e e n v i r o n m e n t s on the s t r e n g t h of adhesive-bonded
a l u m i n u m l a p j o i n t s a r e given i n table 1 7 - 1 . In g e n e r a l , w a r m humid a t m o s -
p h e r e s w e r e much m o r e d e t r i m e n t a l than t e m p e r a t e o r c o l d e r e x p o s u r e s ,
T h e e x p o s u r e of o r g a n i c m a t e r i a l s to s p a c e e n v i r o n m e n t ( r e f . 17-6) has
d e m o n s t r a t e d t h a t epoxy, phenolic, p o l y e s t e r , and silicone-type p o l y m e r s
-11 2
would have no m e a s u r a b l e e q u i l i b r i u m weight l o s s r a t e ( < l o g / c m -sec)
i n a high vacuum at t e m p e r a t u r e s l e s s than 200" F. E x p o s u r e to high
vacuum at e l e v a t e d t e m p e r a t u r e c a u s e d s e r i o u s d e c r e a s e in the s t r e n g t h of
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
p o l y e s t e r l a m i n a t e s but i n c r e a s e d the s t r e n g t h of l a m i n a t e s of t h e o t h e r
r e s i n s . The i n c r e a s e i n s t r e n g t h while at high vacuum w a s not r e t a i n e d
a f t e r subsequent r e t u r n t o n o r m a l a t m o s p h e r i c conditions.
17-1
-
I-
Provided by IHS
~ - -
17, 1.2 E n v i r o n m e n t a l Evaluation of Sandwich

Constructions
Aluminum sandwich p r o p e r l y bonded with epoxy-phenolic o r n i t r i l e -

e l a s t o m e r - p h e n o l i c adhesives showled no significant reduction in s t r e n g t h
a f t e r outdoor weathering exposure f o r 5 y e a r s ( r e f . 17 - 1O ) . L a b o r a t o r y
aging and e x p o s u r e to JP-4 f u e l showed no d e l e t e r i o u s effects on panel
.
s t r e n g t h . E x p o s u r e of a similar construction t o m o r e s e v e r e conditions
. f o r a s h o r t e r t i m e period produced no m a r k e d e f f e c t s ( r e f . 17-1 1 ) .
T h e s e r v i c e h i s t o r y of sandwich of r e i n f o r c e d - p l a s t i c m a t e r i a l s com -
bined with s i m u l a t e d w e a t h e r aging h a s developed data showing wide s c a t t e r
but a n a l y s i s of the information showed t h a t s e r v i c e life r e d u c e d s t r e n g t h
m o r e than did shelf life ( r e f . 17-5). After 3 y e a r s ' exposure at s e v e r a l out-
door sites t h e s a l t - a i r e x p o s u r e a p p e a r e d t o b e the m o s t s e v e r e and produced
a somewhat e r o d e d s u r f a c e on l a m i n a t e s , with e x p o s u r e of s o m e g l a s s f i b e r s
on t h e s u r f a c e ( r e f , 17-12). A s u m m a r y of U . S . A i r F o r c e s e r v i c e e x p e r -
ience showed sandxxich m i t h reinforced p l a s t i c facings had no b a s i c we+kness
except f o r rapid r a i n e r o s i o n ( r e f . 17-9).
E x p o s u r e of sandwich with p a p e r honeycomb c o r e t o 3 y e a r s ' r u r a l

a t m o s p h e r e and 3 y e a r s of e x p o s u r e to s a l t - w a t e r a t m o s p h e r e produced
r a t h e r inconclusive r e s u l t s but indicated good aging p o s s i b i l i t i e s ( r e f . 17-13).
A v a r i e t y of solvent m a t e r i a l s can be s u c c e s s f u l l y r e s i s t e d by bonded

sandwich f o r e x p o s u r e s of 30 days except e x p o s u r e t o paint r e m o v e r s , which
d e g r a d e d s t r e n g t h d r a s t i c a l l y ( r e f . 17-7).
T h e m o s t s e r i o u s and difficult s e r v i c e p r o b l e m is t h a t of w a t e r e n t r y into

t h e sandwich c o r e s , W a t e r accumulation can r e s u l t i n damage to t h e panel
f r o m f r e e z i n g , o r in s u p e r s o n i c , high-altitude a i r c r a f t by boiling, which can
r u p t u r e the c o r e o r panel i t s e l f , and f r o m c o r r o s i o n at the bond i n t e r f a c e s
t h a t d e s t r o y s t h e c h e m i c a l bond ( r e f s . 17-7 and 17-8). Fluid e n t r y c a n a l s o
contribute to' dynamic unbalance and weight gain in s u c h p a r t s as c o n t r o l s u r -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f a c e s and h e l i c o p t e r r o t o r blades. Fluids in r a d o m e s t r u c t u r e affect its
t r a n s m i s s i o n and s t r u c t u r a l c h a r a c t e r i s t i c s . In s e v e r a l i n s t a n c e s , foam
c o r e m a t e r i a l s have failed due t o vibration and have accumulated m o i s t u r e
with resulting c o r r o s i o n of t h e metal f a c e s adjacent to the foam. M o i s t u r e
penetration of b a l s a c o r e panels through t h e edges o r f r o m s e e p a g e a r o u n d
f a s t e n e r s h a s r e s u l t e d in c o r r o s i o n d a m a g e at the m e t a l - a d h e s i v e i n t e r f a c e
with a r e s u l t a n t l o s s of t h e bond.
17 -2
-------
, -.
7
I n s e r v i c e , w a t e r e n t r y o c c u r s p r i m a r i l y during descent s i n c c the lag in
p r e s s u r e and t e m p e r a t u r e changes in the panel m e a n s the i n t e r n a l p r e s s u r e
is l e s s than the e x t e r n a l p r e s s u r e and a p a r t i a l vacuum d r a w s the m o i s t u r e
into the panel through any defect o r omission of the s e a l a n t . In production
o r during fabrication and finishing o p e r a t i o n s , m o i s t u r e m a y e n t c r if panels
are i m m e r s e d o r s p r a y e d with w a t e r o r o t h e r fluids. A l s o , panels with
adhesive bonds with poor m o i s t u r e r e s i s t a n c e o r bonds of a porous natiir(*
and skins o r edges of laminated plastic o r other porous m a t e r i a l s alloxv
fluids t o e n t e r by t r a n s m i s s i o n d i r e c t l y through the m a t e r i a l , though the
quantity depends on the d e g r e e of porosity.
Difficulty m a y r e s u l t even with a fully s e a l e d panel because of one o r

m o r e of the following conditions.
1. High levels of sonic vibration c a u s e s e a l a n t breakdown.
2. S t r u c t u r a l deflection.
3. Differential p r e s s u r e .
4. Inadequate o v e r l a p in bonded joint.
5. E x t e r n a l accidental damage to panel.
6. Inadequate design for s e a l i n g ,
1. T h e r m a l s t r e s s e s due to s t e a m cleaning c a u s e sealing o r bonded

joints to fail.
8. Aging and d e t e r i o r a t i o n of sealing m a t e r i a l s .
9. Inadequate m a t e r i a l p r o p e r t i e s .
T h e techniques and m a t e r i a l s u s e d to provide effective> sealing m u s t take

the above conditions into consideration. The quality of the adhesive bond,
i . e . , d e g r e e of porosity and adhesion q u a l i t i e s , h a s a d i r e c t bearing on its
sealing c h a r a c t e r i s t i c s . Polysulfide and filled epoxy compounds a r e the
m o s t frequently used m a t e r i a l s f o r sealing open c o r e a r e a s , joints between
edge m e m b e r s , relief cutouts, and tool o r vent holes. F o r laminated p l a s -
t i c s k i n s of r a d o m e s o r o t h e r plastic a s s e m b l i e s , the u s e of v o i d - f r e e l a m -
inating techniques and nylon o r epoxy s e a l e r coatings i s recommended.
Another p r o c e d u r e is to u s e nonperforated c o r e to prevent the s p r e a d of
fluids throughout the panel. This r e q u i r e s the u s e of adhesives which give
off little o r no volatiles during c u r i n g of the sandwich panel.
17 - 3
L
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L
__ .~
MIL-HDBK-23A CHG N O T I C E 3 7770 014280 2 T 3
-
b
+
17.2 RAIN EROSION O F PLASTIC
LEADING E D G E S
High-speed flight through r a i n c a u s e s e r o s i o n d a m a g e to t h e e x t e r i o r

p l a s t i c leading e d g e s of flight v e h i c l e s . T h e s e v e r i t y of the r a i n - e r o s i o n
d a m a g e h a s been extensive enough i n s o m e c a s e s to c a u s e a complete s t r u c -
t u r a l f a i l u r e of the p l a s t i c p a r t . S e v e r a l s t u d i e s have b e e n u n d e r t a k e n t o
(1) d e t e r m i n e the m e c h a n i s m of r a i n - e r o s i o n d a m a g e , ( 2 ) evaluate available
and p r o m i s i n g new m a t e r i a l s , ( 3 ) d e t e r m i n e the v a r i a b l e s that m o s t s e r i o u s l y
affect the amount of r a i n - e r o s i o n d a m a g e . T h e r a i n - e r o s i o n evaluation of
m a t e r i a l s and affecting v a r i a b l e s h a s b e e n conducted on a r o t a t i n g - a r m
a p p a r a t u s f o r s u b s o n i c evaluation and on both a r e c o v e r a b l e b a l l i s t i c t e s t
and on a rocket s l e d a p p a r a t u s f o r s u p e r s o n i c evaluation. C o r r e l a t i o n of
t h e l a b o r a t o r y t e s t data h a s b e e n m a d e with s c r v i c e t e s t d a t a a t both s u b -
s o n i c and s u p e r s o n i c s p e e d s . E x t e n s i v e d a t a have b e e n obtained which indi-
c a t e t h a t t h e m o s t c r i t i c a l v a r i a b l e s involved a r e s p e e d of flight, d r o p s i z e --
and r a i n f a l l c o n c e n t r a t i o n , and angle of i m p a c t ( r e f . 17-4).
T h e r e have been no r e i n f o r c e d p l a s t i c l a m i n a t e s o r composite m a t e r i a l

c o n s t r u c t i o n s developed t o date t h a t a r e s a t i s f a c t o r y without protection f o r
s e r v i c e u s e involving e x p o s u r e a t high flight s p e e d s in r a i n f o r extensive
time p e r i o d s .
N e o p r e n e coatings have b e e n u s e d as a m e a n s of protection to p r e v e n t

r a i n - e r o s i o n damage to the p l a s t i c leading edges a t subsonic s p e e d s . A
1 0 - m i l t h i c k n e s s is utilized to obtain the b e s t combination of r a i n - e r o s i o n
p r o t e c t i o n and e l e c t r i c a l t r a n s m i s s i o n p r o p e r t i e s f o r end i t e m u s a g e w h e r e
e l e c t r i c a l r e q u i r e m e n t s a r e involved, s u c h a s r a d o m e s . It h a s b e e n d e t e r -
m i n e d t h a t , f o r optimum p e r f o r m a n c e of t h e c o a t i n g s , i t is e s s e n t i a l that
the coating b e applied to s t r u c t u r a l l y sound m a t e r i a l . F o r n o n e l e c t r i c a l
a p p l i c a t i o n s , t h e u s e of t h i c k e r n e o p r e n e coatings will g r e a t l y i n c r e a s e the
r a i n - e r o s i o n r e s i s t a n c e of the p l a s t i c leading edge. T e m p e r a t u r e limitations
f o r the n e o p r e n e s a r e 3 0 0 " F f o r extended u s e (100 h o u r s ) and 4 0 0 " F f o r
extremely short time periods (minutes).
17 -4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Provided by IHS
I
uIL-HDBK-23A CHG NOTICE 3 9 9 9 9 9 7 0 OL4828L L3T
(17-1) EICKNER, H. W .
1955. Weathering of Adhesive-Bonded Lap-Joints of Clad AlUminum
Alloy. Wright A i r Develop. C e n t e r Tech. Rep. 54-447, P a r t I
(17 - 2 ) EICKNER , H. W .
1957. Weathering of Adhesive-Bonded Lap-Joints of Clad Aluminum
A l l o y . Wright A i r Develop. C e n t e r Tech. Rep. 5 4 - 4 4 ? ,
P a r t II.
(17-3) HEIDBRIER, W . F.
1962. M a t e r i a l - B r a z e d S t a i n l e s s S t e e l Sandwich--Exposure t o
Weathering Under S e a s h o r e Conditions --Effect on Convair
( F o r t Worth). Repot FGT-2948; ( d i s t r i b u t c d u n d e r Contract
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
AF33(657)-11214. A i r F o r c e M a t e r i a l s L a b o r a t o r y , Wright-
P a t t e r s o n A i r F o r c e B a s e , Ohio).
(17-4) L A P P , ROY R . I and OTHERS

1956. T h e Rain E r o s i o n of A i r c r a f t M a t e r i a l s . Wright Air Develop.
C e n t e r Tech. Rep. 55-308.
(17'-5) MARSHALLl A. C.
1959. E f f e c t of N o r m a l -4ging on Strength of G l a s s - F i b e r - Reinforced
P l a s t i c Honeycomb C o r e s . A m e r . Soc. T e s t . M a t c r .
Symposium S T P 270.
(17-6) PODLASECK, S . E . , SUHORSKY, J . , and KRAMER, I . R .

1962. T h e Behavior of O r g a n i c M a t e r i a l s Under Simulated Space
E n v i r o n m e n t a l Conditions. M a r t i n M a r i e t t a S p a c e S y s t e m s
Div. Report RM-130 (under c o n t r a c t NASS-1253 of the National
Aeronautics and Spacc Administration Goddard Space Flight
Center).
(17-7) REESE, J . P .
1960. S e r v i c e E x p e r i c n c c with Sandwich Construction- -Some
Approaches to P r o b l e m s in A i r c r a f t Applications. A m e r .
Soc. T e s t . and M a t e r . Symposium S T P 270.
(17-8) REESE, J . P .
1960. W a t e r E n t r y into Honeycomb P a n e l s . M a r t i n Report ER. 11551
(under B u r e a u of Naval Weapons C o n t r a c t NOas 60-6070-C).
17 -5

L
MIL-HDEK-23A CHG N O T I C E 3 -
9999970 0348282 07b
(17-9) SCHWARTZ, R . T .
1948. U s e of Sandwich Construction i n M i l i t a r y A i r c r a f t . I n s t .
Ae'ro. S c i e n c e s P r e p r i n t 165, T h e o r y and P r a c t i c e of Sand-
wich Construction i n A i r c r a f t .
-
(17 10) THOMAS, J . E .
1962. Material-Adhesives-FMS-0015 (Shell 4225 o r Hexcel HP-422)
and FMS-0016 ( P l a s t i l o c k 620-626)--JP-4 F u e l i n Sandwich
P a n e l s --Effects of Convair ( F o r t Worth). R e p o r t FGT-2855;
(distributed u n d e r C o n t r a c t A F 33(600)-36200, A i r F o r c e
M a t e r i a l s L a b o r a t o r y , Wright P a t t e r s o n A i r F o r c e B a s e , Ohio).
(17-11) TUCKERMAN, A . J .
1959. E f f e c t of Environmental E x p o s u r e on Adhesive-Bonded Stuc-
t u r e s . A m e r . Soc. T e s t . and M a t e r . Symposium S T P 270.
(17-12) WERREN, F R E D , and HEEBINK, B.G.

1955. Interim R e p o r t on Weathering of G l a s s - F a b r i c - B a s e P l a s t i c
L a m i n a t e s . Wright A i r Develop. C e n t e r Tech. Rep. 55-319.
(17-13) Z E M E R , ROBERT F.
1959. Effect of N a t u r a l E n v i r o n m e n t on Sandwich S t r u c t u r e with
AMS 3722 P a p e r Honeycomb C o r e . A m e r . Soc. T e s t . and
M a t e r . Symposium S T P 2 7 0 .
17 -6
-- -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

T a b l e 17-l.--Performance of bonded 1 / 2 - i n c h o v e r l a p j o i n t s
of 0.065-inch aluminum a f t e r w e a t h e r i n g
exposurd
Exposure-2 : N i t r i l e - : Polyvinyl-: Epoxy : Epoxy- :Polyamide-

: elastomer-: phenolic : :phenolic :elastomer-
___-__-__-_--_--__._----------.-----------.----------.---------.----------
: p h e n o l i c : : phenolic
: (Percent) : (Percent) : (Percent) :(Percent) : (Percent)
Madison, W i s .
3 months
s tnrset sr es sesde d :: 90 - 110

110 :: 85 - O
105 :: 85 - 90 :: 105 :: 85
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
u 95 95 100 95 95 90
12 months
stressed : 80 . 100 : 90 - 105 : 40 - 85 : 95 : 90
unstressed : 105 - 115 : 100 - 105 : 65 - 95 : 100 : 95
36 months
stressed : 70 - 90 : 85 - 95 : 30 --- 85
unstressed : 105 - 130 : 95 - 100 : 80 --- 105
Panama Canal Zone :

3 months
stressed : 85 - 95 : 95 : 0 - 9 0 : 95 : 55
unstressed
12 months : 100 - 105 : 85 - 115 : 15 - 80 : 100 : 70
stressed : 85 - 95 : 90 - 110 : O - 15 : 85 :
O
u nstressed
36 months : 95 - 105 : 95 - 100 : O - 80 : 90 :
30
O
stressed : 80 - 90 : 45 - 85 : --- 30
unstressed : 80 - 115 : 75 - 95 : O - 40 : --- 20
F a i r b a n k s , Alaska :
3 months
stressed : 95 - 110 : 95 - 105 : 35 - 90 : 100 : 100
uns t r e s s e d : 100 - 110 : 100 : 80 - 95 : 100 : 105
1 2 months
stressed : 95 - 100 : 95 - 110 : 45 - 90 : 95 : 100
unstressed : 105 - 110 : 95 - 100 : 85 95 : 90
36 months
stressed 70
uns t r e s s e d :
: 100
85 -- 90
105 :: - 105 ::
90 95 0-80
90
: 95
95
:
: 70
(Page 1 of 2)

-~ __-___- ~
Table 17-l.--Performance of bonded 1 / 2 - i n c h o v e r l a p j o i n t s

of 0.065-inch aluminum a f t e r w e a t h e r i n g
e x p o s u r d ( c o n t .)
: ( P e r c e n t ) : ( P e r c e n t ) : ( P e r c e n t ) :( P e r c e n t ) : ( P e r c e n t )
New Mexico
3 months
unstressed : 100 - 105 : 90 - 105 : 90 - 100 : 105 : 90
1 2 months
unstressed : 95 - 115 : 95 - 100 : 90 : 100 : 90
36 months
unstressed : 105 - 135 : 95 - 100 : 85 - 95 95 : 100
Florida
3 months
unstressed : 95 - 105 : 100 - 115 : 70 - 85 : 95 : 90
1 2 months
unstressed : 95 - 105 : 75 - 100 : O - 75 : 95 : 75
36 months
unstressed : 5 - 5 5 : 0 - 1 0 0 : 15 --- . O
1
-Values t a b u l a t e d a r e p e r c e n t a g e s of unexposed c o n t r o l s t r e n g t h s ( r e f . 1 7 - 1
and 1 7 - 2 ) .
2
-Exposures d e s i g n a t e d " s t r e s s e d " r e f e r t o p a n e l s i n which t h e l a p j o i n t s
were s u b j e c t e d t o bending s t r e s s d u r i n g exposure.
(Page 2 of 2)
*U.% GOVERNMENT PRINTING OFFICE: 1969-343-224/838
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

r--
NIL-HDRK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 0148285 8 8 5 m
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
MIL-HDBK-23A
9 March 1972
CHAPTER 18 -- "OPTIMLJP" SANDWICH
Page
18,l Introduction 18-1

18.2 Sandwich Weight 18-1
18.3 Sandwich Bending S t i f f n e s s 18-3
18,4 Sandwich Bending Moment C a p a c i t y 18-8

-- ~~ ~ --
MIL-HDBK-23A CHG N O T I C E 3 H 9 9 9 9 9 7 0 0 1 q 2 b 711
.
c
MIL-HDBK-23A
9 March 1972
CHAPTER 18
liOPTIMUMii SANDWICH
18. 1 INTRODUCTION
The concept of sandwich construction combining thin, strong facings

on lightweight, thick c o r e s suggests possibilities of deriving construc-
t'ions s o proportioned that minimum-weight constructions, often called
lloptimum'l constructions, f o r a given stiffness o r loading capability a r e
attained. It is important to r e a l i z e t h a t the minimum-weight construc-
tion derived m a y not be p r a c t i c a l because floptimization" m a y r e q u i r e
unusually thin facings which m a y not be available, o r unusually light-
weight c o r e s of g r e a t thickness. P r e v i o u s chapters f o r design of specific
sandwich components will give c o r r e c t sandwich proportions regarding
s t r e s s e s in facings and c o r e , buckling, o r deflections; but t h e s e sand-
wiches m a y not be m i n i m u m weight. Examples will be given t o i l l u s t r a t e
t h i s point.
D i r e c t optimization without examination of the r e s u l t a n t designs may

lead to e r r o n e o u s conclusions when comparing material r e q u i r e m e n t s
with constructions other than sandwich because the lloptimizedll sandwich
m a y not be a r e a l i s t i c one.
Intuitive optimization such a s requiring that a l l p a r t s be fully

s t r e s s e d o r that f a i l u r e occur i n a l l modes simultaneously does not
n e c e s s a r i l y produce minimum-weight s t r u c t u r a l components (ref. 18-6).
18.2 SANDWICH WEIGHT
The weight of a sandwich i s given by t h e f o r m u l a
W = w t t w t t w t t w
1 1 2 2 c c B
W = 2wt t w t t W (for equal facings)
c c B
18- 1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I --Provided by IHS
I
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O348287 6 5 8 m
MIL-HDBK-23A
9 March 1972
w h e r e W is sandwich weight ( p e r unit sandwich a r e a ) ; w i s density;
t is thickness; s u b s c r i p t s 1 and 2 denote facings 1 and 2 ; s u b s c r i p t c
denotes c o r e ; and W is total weight of bond ( p e r unit sandwich a r e a )
B
between facing and c o r e , This bond m a y be an adhesive o r b r a z e
material. If it is a s s u m e d the bond weight i s the s a m e for a l l sandwich
of the type considered, then weight comparisons can be made on the
b a s i s of (W - WB). It i s a l s o convenient to e x p r e s s t C a s (h - ;
t2)
w h e r e h is distance between facing centroids. Then formulas (18:l) and

(18:la) can- be r e w r i t t e n as
(W-W ) = @ tt @ t t w h (18:2)
B 11 2 2 C
(W - W B ) = 2 @ t3-w h C
(18:Za)
where
W W W
=wl
- -2 C
Y
@,=w
2
- - 2C @ = u r - -
2
C
It is essential that the weight units be consistent in using the formulas.

Thus if w is density i n pounds p e r cubic inch, t and h m u s t be in inches
and then (W - WB) is weight i n pounds p e r s q u a r e inch of sandwich a r e a .
Example: Compute (W - W ) f o r a sandwich with O. 032-in.
B
aluminum facings on a 3/4-in. honeycomb c o r e having a density of
6 pcf. Using f o r m u l a (18:2a)
(W - W B ) = 2(0.1000 - O. 00174)(0. 032) t O. 0035(0.782)

(W - WB ) = O. 00629 t O. 00274 = O. 0 0 9 0 3 psi
or
(W - WB ) = 144(0.00903) = 1.30 psf
18-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

- -_
MIL-HDBK-23A CHG N O T I C E 3 W 7777770 0 1 4 8 2 8 8 574
b
c
MIL-HDBK- 2 3A
9 March 1972
18.3 SANDWICH BENDING STIFFNESS
Since the p r i m a r y purpose of s t r u c t u r a l sandwich is to provide

stiffness, hence low deflection under t r a n s v e r s e load and high r e s i s t a n c e
to buckling under edgewise (in-plane) load, a minimum-weight sandwich
t o provide a specified bending stiffness can be determined.
The bending stiffness of a sandwich, p e r unit width, is given by the

f o r mula
--
E2t2
Al x2 h2
D = (18 :3)
E2t2
D = -E t h2 (18:3a)
2A
w h e r e D is bending stiffness; s u b s c r i p t s 1 and 2 denote facings 1 and 2;

E is facing e l a s t i c modulus; A i s one minus the product of two Poisson's
r a t i o s ; t is facing thickness; and h is distance between facing centroids.
Substitution of the stiffness expression (18:3) into the weight equation

(18:2) and minimizing the weight by calculus (ref. 18-4) r e s u l t s in the
following expressions f o r h and t to produce minimm-weight sandwich
'for a r e q u i r e d stiffness D.
2
(18:4)
3
h =- 8D$A (18 :4a)
W E
C
18-3
------------
I --Provided by IHS .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

I
MIL-HDBK-2 3A
9 March 1972
and
(18:5)
hWc
t = -h- wc (18:5a)
4 @
The resultant construction w i l l be found to be proportioned s o that

approximately two-thirds of the sandwich weight will be in the c o r e
(refs. 18-1, 18-2, 18-3, 18-4, 18-5).
Example: Determine dimensions of sandwich components s o t h a t

6 2
the resultant composite w i l l have a bending stiffness D = 3 . O X 10 lb-in.
7
p e r in. of width. The facing p r o p e r t i e s a r e E / X = 10 psi,
1 1
6
w = 0.100 pci, E2/X2 = 3 X 10 psi, w = O. 061 pci, and the c o r e weight
1 2
w = 0.0034 pci.
C
18-4
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

_- ____
NIL-HPBK-23A CHG N O T I C E 3 U 7977770 0348270 342 W
c MIL-HDBK-2 3A
9 March 1972
Minimum weight de6ign- -

From f o r m u l a (18:4)
and f r o m f o r m u l a s (18:5)
O. 0034
= O * 033 in*
t1 = 2 * 33
O. 0 9 8 3
With t h e s e dimensions the sandwich weight (minus bond weight) is

O. 0237 p s i of which O. 0156 p s i is in the c o r e , O. 0033 p s i i n facing 1, and
O. 0048 p s i in facing 2. About two-thirds of the sandwich weight is in
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
the core.
Minimum weight design f o r sandwich with equal f a c i n g s - -
Sandwich with both facings of type 1--
18-5

-I --
= 9999970 OL4829L =
.-
- -__-
MIL-HDBK-23A CHG N O T I C E 3 O9
MIL- HDBK- 2 3A
9 March 1972
From formula (18:4a)
h =
I
(3)(lo ')(O. 09 83 )
O. 0034(10 ) '
-7 1I' = 4.11 in.
and f r o m f o r m u l a (18:5a)
4.10(0. 0034)
t = = 0 . 0 3 5 in.
4(0.00983)
The sandwich weight (minus bond weight) is O. 0 2 0 9 p s i of which

O. 0139 p s i is i n the c o r e and O. 0070 p s i is in the facings. The c o r e
weight is 66 percent of the sandwich weight.
Sandwich with both facings of type 2--
F r o m f o r m u l a (18:4a)
O. 0034(3)(10")
J
and f r o m f o r m u l a (18:5a)
5.19(0. 0034)
t = = O. 074 in.
4(0. 0593)
The sandwich weight (minus bond weight) i s O. 0262 psi of which

O. 0171 psi, o r 65 percent, is c o r e weight.
18-6
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG NOTICE 3 9999970 0348292 T35 =
MIL-HDBK- 2 3A
9 March 1 9 7 2
A s u m m a r y of the dimensions is shown i n table 18-1.
Tab1.e 18-1. --Summary table of component dimensions

f o r m i n i m u m weight sandwich
Types 1 and 2 : 4.66 : 0.033 : 0.078 : O. 0237
Both facings type 1 : 4. 11 : .O35 : .O35 : .O209
Both facings type 2 : 5.19 : .O74 : .O74 : .O262

~
:::Does not include bond weight.
The values in table 18-1 show that the lightest sandwich is that
with both facings of type 1 m a t e r i a l (facing with the lower value of
(A/E). The thinnest facing of type 2 m a t e r i a l i s obtained when both
facings a r e of type 2 but this produces a sandwich about 10 p e r c e n t
h e a v i e r than one of m i n i m u m weight.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
18-7
-----____
..---
-~ ~
-- -
1
P

F
MIL-HDBK-23A
9 March 1972
18.4 SANDWICH BENDING MOMENT CAPACITY
The bending m o m e n t r e s i s t a n c e of a sandwich with thin, equal

facings on a c o r e of negligible bending stiffness i s given by the
f o r mula
M = Fth (18:6)
w h e r e M is bending moment p e r unit width; F is facing s t r e s s ; t is

facing thickness; and h is distance between facing centroids. Solving
f o r m u l a (18:6) f o r t and substitution of t h i s into the weight equation
(18:2a) and minimizing with r e s p e c t to h (ref. 18-4) r e s u l t s in
2 2M$
h = (18:7 )
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Fw
C
and finally
hw
(18:8)
Comparison of t h e s e e x p r e s s i o n s with those based on stiffness c r i t e r i a

show that facings could be about twice a s thick f o r m o m e n t r e s i s t a n c e
c r i t e r i a as f o r stiffness c r i t e r i a and t h a t h values a r e dependent on
relative stiffness and bending moment requirements. The r e s u l t a n t
construction w i l l have about half its weight i n the c o r e .
18-8

MIL-HDBK-23A
9 March 1972
Example: Determine dimensions of sandwich components s o that

the r e s u l t a n t composite will have a bending moment r e s i s t a n c e of
7,000 in. -1b p e r in. of width. The facing p r o p e r t i e s a r e F = 45,000 p s i
yield s t r e s s and w = O. 100 pci and the c o r e weight w = O. 0034 pci.
C
F r o m f o r m u l a (18:7)
and f r o m f o r m u l a (18:8)
3.00(0. 0034)
t =
2(0. 0983)
= O. 052 in, -
With t h e s e dimensions the sandwich weight (minus bond weight) i s

O. 0204 p s i of which O. 0101 p s i o r about 50 p e r c e n t is in t h e c o r e .
Example: D e t e r m i n e dimensions of sandwich components so that

the r e s u l t a n t c o m p o s i t e - w i l lhave a bending moment r e s i s t a n c e of a t
least 7, O00 in. -1b p e r in. of width and a bending stiffness of a t l e a s t
6 2
D = 3 X 10 lb-in. p e r in. of width. The facing p r o p e r t i e s a r e
7
E/X = 10 psi, w = O. 100 pci, and w = O. 0034 pci.
C
F r o m t h e example in 18.3 the minimum-weight sandwich f o r the

r e q u i r e d stiffness will have h = 4.11 i n . , t = O. 035 in.., and weight,
W = O. 0209 psi. F r o m f o r m u l a (18:6) the facing s t r e s s in t h i s sand-
wich due t o bending moment is
F = 7' 'Oo = 48,600 p s i

O. 035(4.11)
and a n alloy s t r o n g e r than t h i s s t r e s s m u s t be u s e d in the facings.

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
18-19

MIL-HDBK-23A
9 March 1972
If an alloy with a yield stress of only 20, O00 p s i m u s t be used, the

design m u s t be changed a s follows, based on bending moment c r i t e r i a
4.50(0. 0034)
t = = 0.078 in.
2(0.0983)
T h e s e dimensions a r e l a r g e r t h a n t b s e n e c e s s a r y f o r r e q u i r e d stiffness,
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
thus the stiffness will be much m o r e than needed (nearly t h r e e t i m e s a s

stiff). The sandwich weight (minus bond weight) is O. 0306 p s i which i s
about 46 p e r c e n t heavier than needed f o r stiffness c r i t e r i a only. Thus
the u s e of a s t r o n g e r facing alloy would be distinctly advantageous.
The facing s t r e s s , F, should not exceed wrinkling o r dimpling

s t r e s s e s given by p r o c e d u r e s in chapters 3 and 4.
18.5 SANDWICH PANEL BUCKLING
The load at which general buckling of sandwich panels o c c u r s is

given by the formula
7r
2
IT = K-D
b2
w h e r e N is buckling load p e r unit panel width; K is a coefficient

dependent upon type of loading, type of edge s u p p o r t , . p a n e l aspect
ratio, and a s h e a r p a r a m e t e r , V; b i s panel width; and D is sandwich
2 2
bending stiffness per unit width. The p a r a m e t e r V = IT D/b U where
U is the sandwich s h e a r stiffness. V is usually quite s m a l l and the
dependence of K upon V i s of a secondary nature: thus the proportion
of sandwich components t o produce a minimum-weight construction
having a given value of N will be v e r y n e a r l y the s a m e a s f o r a sandwich
designed t o have m i n i m u m weight and a specified stiffness (18. 3). It
is possible t o minimize weight based on panel buckling c r i t e r i a but
m o s t often s o difficult that first approximations based on stiffness
c r i t e r i a suffice. An example is given t o demonstrate procedure.
18- 10
------- -----

- - ~~
~--
-
MIL HDBK- 2 3A
9 March 1972
Example: D e t e r m i n e dimensions of sandwich components such
that a s i m p l y supported panel 40 in. wide and 80 in. long will not
buckle under a load (applied on the 40-in. s i d e ) of 40, O00 lb. The
7
facing p r o p e r t i e s a r e E/X = 10 p s i and w = O. 100 pci and the c o r e
p r o p e r t i e s w = O. 0034 pci and G = 2 0 , 0 0 0 psi.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C C
F o r this panel the buckling coefficient is
4
K = (18:lO)
(1 t v)2
and combining this e x p r e s s i o n with (18:9) and the weight equation

(18:la) and minimizing t h e weight (ref. 18-4) r e s u l t s in:
2 2
3 N b (1 t V )
h =
W
W
t = h(l - V)-4w C
F o r t h i s example, w /4w = O. 0085

C
then
t = 0.0085h(l - V)
18 11-

___- ~ _ _ _ _ _ _ _ -
MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 1 4 8 2 9 7 5T7 =
-
MIL HDBK-2 3A
9 March 1972
A s s u m e values of V and compute h and t, then
-
V -h -t
O O. 984 O. 0084
O. 05 1.035 O. 0084
o. 10 1.086 O. 0083
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O. 15 1. 141 O. 0082
This tabulation of values shows that v a r i a t i o n s in V have little influence

on h and p r a c t i c a l l y no influence on t.
A s s u m e t = O. 0085 i n . , then the facing stress is
F=-=
2 t O. 0170
''
'Oo = 5 9 , 0 0 0 p s i
Thus a s t r o n g facing m a t e r i a l m u s t be used; and if the c o r e is a honey-

comb, it m u s t have a v e r y small c e l l s i z e to prevent f a c e dimpling.
Assuming t h e s e a r e possible, the a c t u a l value of V can be calculated.
A s s u m e h = 1 in. Then
rZthE/l 2 7
(O. 0085)(1)(10 1
v= -- 2(1,600)(20,000)
= o. 0131
2b2G
C
This value of V is s o small that the effect of V is indeed negligible.
The weight of this panel is
W = l(0.0034) t O. 017(0.100) = O. 0051 p s i
18-12

MIL-HDBK-23A CHG N O T I C E 3 m 9999970 OL4829 4 3 3 m
- MIL- HDBK- 2 3A
9 March 1972
Choose a t h i c k e r facing to lower the s t r e s s - -

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f o r t = 0 . 0 2 0 in., F = -
1,000
O. 04
= 25,000 psi
Then solving formulas(18:9) and (18:lO) f o r D and finally h r e s u l t s in
h = O. 64 in. for V = O
h = O. 65 in. f o r V = O. 0197 f o r t = O. 0 2 0
The weight of t h i s panel is
W = O. 65(0.0034) t O. 040(0.100) = O. 0062 p s i
which is a reasonable value; but i s about 20 percent heavier than for

sandwich with O. 0085-in. facings.
18 i3-
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MIL-HDBK-23A CHG NOTICE 3 m 9 9 9 9 9 7 0 0148299 37T m
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REFERENCED DOCUMENTS --
(18-1) ENGEL, H. C., HEMMING, CHARLES B., and MERRIMAN, H. R.
1950. S t r u c t u r a l Plastics. McGraw Hill.
(18-2) ENGEL, H. C. and TRUNELL, W. W.

1944. S t r u c t u r a l Composite P l a s t i c M a t e r i a l s .
Sept.
- Modern Plastics.
(18-3) GERARD, GEORGE

1956. Minimum Weight Analysis of C o m p r e s s i o n S t r u c t u r e s ,
- N.Y. Univ. Press.
(18-4) KUENZI, EDWARD W.

1970. Minimum Weight S t r u c t u r a l Sandwich. U. S. F o r e s t Serv.
Res. Note FPL-086.
(18-5) PERRY, DAVID J.

1950. A i r c r a f t Structures. McGraw Hill.
(18-6) SHEN, C. Y . , and PRAGER, W.

1968. Recent Developments in Optimal S t r u c t u r a l Design. Appl.
Mech. Rev. Oct.
*V.S. GOVERWMEKT PRIKTING OFFICE: 1872-714-165/ 13844
18-14
.
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I ~
MIL-HDBK-23A CHG N O T I C E 3 H 9999970 0348300 9 3 1 M
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MIL -HDBK-23A
CHAPTER 19 -- DESIGN OF
SANDWICH STRIPS UNDER TORSION LOAD
Page
19.1 Scope 19-1
19.2 Design and Checking Procedures 19-1
19.2.1 Determining Facing Thickness, Core Thickness
and Core Shear Modulus For Sandwich Strips
of Trapezoidal and Rectangular Cross Section 19 -2
19.2.1.1 Determination of Minimum Values of h and t 19 -3
19.2.1.2 Determination of Actual Values of h and t 19 -3
19.2.1.3 Checking Procedure For Sandwich Strips of
Trapezoidal and Rectangular Cross Section 19 -4
19.2.2 Determining Facing Thickness and Core Shear
Modulus For Sandwich Strips of Triangular
Cross Section 19-4
19.2.2.1 Determination of Minimum Values of t 19 -6
19.2.2.2 Determination of Actual Values o f t 19 -6
19.2.2.3 Checking Procedure For Sandwich Strips o f
Triangular Cross Section 19 -7
.
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- Licensee=GKN Westland Aerospace Ltd/9961819100, User=perry, richard
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MIL-HBBK-23A CHG N O T I C E 3 7777770 O l 1 4 8 3 O L 8 5 8 W
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CHAPTER 1 9
DESIGN O F SANDWICH STRIPS UNDER TORSION LOAD
19.1 SCOPE
The d e s i g n of sandwich s t r i p s under t o r s i o n load i s based p r i m a r i l y upon

l i m i t a t i o n s on t h e amount of t w i s t r a t h e r than l i m i t a t i o n s upon torque-produced
s t r e s s e s i n sandwich f a c i n g s o r c o r e .
Design information i s presented f o r sandwich s t r i p s of t r a p e z o i d a l and

t r i a n g u l a r c r o s s s e c t i o n . S t r i p s of r e c t a n g u l a r c r o s s s e c t i o n a r e included
a s a l i m i t i n g c a s e of t h e t r a p e z o i d a l c r o s s s e c t i o n . The information pre-
sented a p p l i e s t o s t r i p s having t h i n , i s o t r o p i c f a c i n g s of e q u a l t h i c k n e s s .
Design procedures f o r sandwich s t r i p s a r e arranged i n a manner s i m i l a r

t o t h e d e s i g n of o t h e r sandwich components wherein f a c i n g and core t h i c k n e s s e s
and p r o p e r t i e s can be determined f o r sandwich having a fixed w i d t h , l e n g t h ,
and t o r s i o n a l r i g i d i t y . The shape of t h e c r o s s s e c t i o n may be determined by
nons t r u c t u r a 1 design fea t u r e s such a s a irf o i l c h a r a c t e r i s t i c s t h a t r e q u i r e
a s p e c i f i e d angle between sandwich f a c i n g s and a d e f i n i t e width of s t r i p a s
f o r a c o n t r o l s u r f a c e . Checking procedures a r e a l s o presented.
A u s e f u l d e s i g n h i n t f o r sandwich s t r i p s of any shape of c r o s s s e c t i o n

i s t h a t t h e torque i s d i r e c t l y p r o p o r t i o n a l t o f a c i n g t h i c k n e s s f o r a given
t w i s t , f a c i n g s t r e s s , o r core s t r e s s . The following procedures a r e r e s t r i c t e d
t o l i n e a r e l a s t i c behavior.
19.2 DESIGN AND CHECKING PROCEDURES

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Assuming t h a t a design begins w i t h chosen design s t r e s s e s and a given

load t o t r a n s m i t , a sandwich s t r i p under t o r s i o n load s h a l l be designed t o
comply w i t h t h e f o u r b a s i c design p r i n c i p l e s summarized i n 1 . 2 of t h e
I n t r o d u c t i o n . These f o u r c o n d i t i o n s m u s t be met.
Detailed procedures g i v i n g t h e o r e t i c a l formulas and graphs f o r determining

dimensions of f a c i n g s and c o r e , a s w e l l a s necessary core p r o p e r t i e s , a r e given
i n following paragraphs. Facing modulus of r i g i d i t y v a l u e s , G , and s t r e s s
v a l u e s , Fs, s h a l l be v a l u e s a t t h e c o n d i t i o n s of u s e ; t h a t i s , i f a p p l i c a t i o n
i s a t e l e v a t e d temperature , then f a c i n g p r o p e r t i e s a t elevated temperature
s h a l l be used i n d e s i g n .
19-1

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19.2.1 DETERMINING FACING THICKNESS, CORE THICKNESS

AND CORE SHEAR MODULUS FOR SANDWICH STRIPS OF
TRAPEZOIDAL AND RECTANGULAR CROSS SECTION
T h i s s e c t i o n g i v e s p r o c e d u r e s f o r d e t e r m i n i n g sandwich f a c i n g and c o r e
t h i c k n e s s e s and c o r e s h e a r modulus s o t h a t chosen d e s i g n f a c i n g s t r e s s e s
and a l l o w a b l e sandwich t w i s t w i l l n o t be exceeded ( r e f . 1 9 - 1 ) .
The a n g l e of t w i s t on one end of a t r a p e z o i d a l sandwich s t r i p of

1 e n g t h . L r e l a t i v e t o t h e o t h e r end i s g i v e n by t h e formula
(19:l)
where 6 i s a n g l e of t w i s t ( r a d i a n s ) , k l i s a c o e f f i c i e n t dependent upon

a v a l u e of V and R , T i s a p p l i e d t o r q u e , b i s w i d t h of sandwich s t r i p , h i s
d i s t a n c e between c e n t r o i d s of sandwich f a c i n g s , t i s t h i c k n e s s of sandwich
f a c i n g ( s e e f i g . 19-1 f o r n o t a t i o n ) , G i s modulus of r i g i d i t y of sandwich
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
f a c i n g , and V and R a r e g i v e n by t h e f o r m u l a s
V = thG (19:2)
2
2b Gc
(19:3)
where Gc i s c o r e s h e a r modulus,Q i s t h e a n g l e shown i n f i g u r e 1 9 - 1 , and

t h e r e m a i n i n g symbols a r e a s d e f i n e d p r e v i o u s l y .
The f a c i n g s h e a r s t r e s s i s maximum n e a r t h e c e n t e r of t h e s t r i p w i d t h
and i s gi,ven by t h e formula
(19 :4)
where F, i s f a c i n g s h e a r s t r e s s , t h e k2 i s a c o e f f i c i e n t dependent upon

v a l u e s of V and R.
The c o r e s h e a r s t r e s s i s maximum a t t h e t h i n n e r edge of t h e s t r i p

and i s g i v e n by t h e formula
(19:5)
where Fsc i s c o r e s h e a r s t r e s s and kg i s a c o e f f i c i e n t dependent upon
v a l u e s of V and R .
19-2
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Combining formulas (19:l) and (19:4) and s o l v i n g f o r h r e s u l t s i n
(19:6)
Graphs of kl and k2 a r e g i v e n i n f i g u r e s 19-2 t o 19-5 wherein t h e s e c o e f f i c i e n t s

a r e presented a s f u n c t i o n s of V and R .
I 19.2.1.1 DETERMINATION OF MINIMUM VALUES OF h AND t
Minimum v a l u e s of h and t w i l l be determined by assuming V = O f o r a

f i r s t approximation. The v a l u e s of h and t and minimum because V = O
o n l y i f t h e c o r e s h e a r modules i s i n f i n i t e ; f o r any a c t u a l c o r e t h e s h e a r
modulus i s n o t i n f i n i t e , hence t h i c k e r c o r e s and f a c i n g s must be used.
Values of k l and k2 f o r V = O a r e obtained from t h e graphs of f i g u r e s 19-2
and 19-4 and s u b s t i t u t e d i n t o formula (19:6) t o o b t a i n a minimum value of h .
S u b s t i t u t i o n of t h i s v a l u e of h i n t o formula (19:4) and s o l v i n g f o r t

r e s u l t s a l s o i n a minimum v a l u e f o r t.
I f t h e r e s u l t a n t v a l u e of t i s t o o small f o r a r e a s o n a b l e f a c i n g t h i c k n e s s ,
i t w i l l be n e c e s s a r y t o lower t h e v a l u e of t h e f a c i n g s t r e s s Fs and begin t h e
d e s i g n a g a i n w i t h formula (19:6).
I 19.2.1.2 DETERMINATION OF ACTUAL VALUES OF h AND t
Since a c t u a l c o r e s h e a r modulus v a l u e s a r e not v e r y l a r g e , v a l u e s of

h and t somewhat g r e a t e r t h a n t h a t g i v e n by formulas (19:6) and (19:4)
must be used. A c t u a l v a l u e s of h can be determined from formula (19:6)
w i t h v a l u e s of k1 and k2 read from t h e graphs of f i g u r e s 19-2 through 1 9 - 5
f o r V # O . I n u s i n g t h e s e graphs i t i s n e c e s s a r y t o i t e r a t e because V
i s d i r e c t l y p r o p o r t i o n a l t o h and t and R i s dependent upon h . A s a n
a i d t o f i n a l l y determining h and G c , f i g u r e 19-6 p r e s e n t s a number of
l i n e s r e p r e s e n t i n g V f o r v a r i o u s v a l u e s of Gc w i t h V ranging from 0 . 0 1 t o
2 and G, ranging from 1,000 t o 1,000,000 p s i . The following procedure
i s suggested:
1. Determine R from formula (19:3) u s i n g t h e minimum v a l u e of h

from 19.2.1.1.
2 . Determine k l and k2 from f i g u r e s 19-2 and 19-4 using a value
of 0.01 f o r v.
3 . Compute h w i t h formula (19:6) and w i t h t h i s value of h compute

a new v a l u e of R u s i n g formula (19:3).
4. Repeat s t e p s 2 and 3 u n t i l t h e v a l u e of h from (19:6) a g r e e s w i t h
t h e v a l u e used i n (19:3) t o compute R .
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24 A p r i l 1974
5. Compute t w i t h formula (19:4) solved f o r t
t = k2T
2hbFs
6. Compute t h e c o n s t a n t r e l a t i n g V t o Gc
7. With t h i s c o n s t a n t e n t e r f i g u r e 19-6 and determine n e c e s s a r y G c .
8 . I f t h e s h e a r modulus i s o u t s i d e t h e range of values f o r m a t e r i a l s

a v a i l a b l e , s l i d e up t h e a p p r o p r i a t e l i n e f i g u r e 19-6 and pick a new value
f o r V , f o r a reasonable value of core shear modulus.
9. Reenter f i g u r e s 2 and 3 w i t h new value of V and r e p e a t previous s t e p s .
19.2.1.3 CHECKING PROCEDURE FOR SANDWICH STRIPS OF
TRAPEZOIDAL AND RECTANGULAR CROSS SECTION
The d e s i g n s h a l l be checked by u s i n g t h e graphs of f i g u r e s 1 9 - 2 t o

19-8 t o determine t h e k c o e f f i c i e n t s and formulas ( 1 9 : 1 ) , ( 1 9 : 4 ) , and
(19:5) t o determine t h e o r e t i c a l performance.
I f t h e r e c t a n g u l a r c r o s s s e c t i o n i s enclosed t h e angle of t w i s t can

be estimated by elementary t h e o r y f o r t o r s i o n of r e c t a n g u l a r c r o s s s e c t i o n s .
The c o e f f i c i e n t kl f o r enclosed , thin-walled , r e c t a n g u l a r c r o s s s e c t i o n s
is given i n t h e graph of f i g u r e 1 9 - 9 .
19.2.2 DETERMINING FACING THICKNESS AND CORE SHEAR MODULUS

FOR SANDWICH STRIPS OF TRIANGULAR CROSS SECTION
T h i s s e c t i o n g i v e s procedures f o r determining sandwich f a c i n g t h i c k n e s s

and c o r e s h e a r modulus s o t h a t chosen design f a c i n g s t r e s s e s and allowable
sandwich t w i s t w i l l n o t be exceeded ( r e f . 19-1).
The a n g l e of t w i s t of one end of a t r i a n g u l a r sandwich s t r i p of l e n g t h L

r e l a t i v e t o t h e o t h e r end i s given by t h e formula
e =k 11TL
(19:7)
8tb3G
where 6 i s angle of t w i s t ( r a d i u s ) , kll i s a c o e f f i c i e n t dependent upon
values of W a n d a , T i s a p p l i e d t o r q u e , b i s width of sandwich s t r i p ,
19-4

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t i s t h i c k n e s s of sandwich f a c i n g , a
i s t h e a n g l e shown i n t h e s k e t c h of
n o t a t i o n i n f i g u r e 19-10, G i s modulus of r i g i d i t y of sandwich f a c i n g ,
and W i s g i v e n by t h e formula
(19:8)
where Gc i s c o r e s h e a r modulus and t h e remaining symbols a r e a s d e f i n e d

previously.
. The f a c i n g s h e a r s t r e s s i s maximum n e a r t h e c e n t e r of t h e s t r i p w i d t h
and i s g i v e n by t h e formula
= k22T
Fs - (19:9)
4tb2
where Fs i s f a c i n g s h e a r s t r e s s , and k22 i s a c o e f f i c i e n t dependent upon
v a l u e s of W a n d U .
The c o r e s h e a r s t r e s s i s maximum a t t h e t h i c k e r edge of t h e s t r i p and

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
i s g i v e n by t h e formula
= k33T
Fsc - ( 1 9 :10)
4b3
where Fsc i s c o r e s h e a r s t r e s s and k33 i s a c o e f f i c i e n t dependent upon
v a l u e s of W a n d a ,
S o l u t on of f o r m u l a s (19:7) and (19:9) f o r f a c i n g t h i c k n e s s , t , r e s u l t s

i n f o r f o l l o w i n g two e x p r e s s i o n s
(19 :11)
and
t = -k2 2T
( 19 :12)
4b 2F s
and t h e l a r g e r v a l u e determined by ( 1 9 : l l ) o r (19:12) m u s t be used t o

prevent excessive t w i s t o r s t r e s s .
19-5
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MIL-HDBK-23 A
24 A p r i l 1974
19.2.2.1 DETERMINATION OF MINIMUM VALUES OF t
A minimum v a l u e of t w i l l be determined by assuming W = O f o r a f i r s t

a p p r o x i m a t i o n . The v a l u e of t i s minimum because W = O o n l y i f t h e c o r e
s h e a r modulus i s i n f i n i t e ; f o r any a c t u a l c o r e t h e s h e a r modulus i s n o t
i n f i n i t e , hence a t h i c k e r c o r e must be u s e d . Values of kll and k22 f o r
W = O a r e o b t a i n e d from t h e g r a p h s of f i g u r e s 19-11 and 19-12 and s u b s t i t u t e d
i n t o f o r m u l a s ( 1 9 : l l ) and (19:12) t o o b t a i n minimum v a l u e s of t . The l a r g e r
v a l u e from f o r m u l a s (19:ll) and (19:12) w i l l be t h e v a l u e of t f o r W = O .
I f t h i s v a l u e of t i s t o o s m a l l f o r a r e a s o n a b l e f a c i n g t h i c k n e s s , i t w i l l
be n e c e s s a r y t o lower t h e v a l u e s of t w i s t , 8 , and f a c i n g s t r e s s , F,, and
b e g i n the d e s i g n a g a i n w i t h f o r m u l a s ( 1 9 : l l ) and ( 1 9 : 1 2 ) .
19.2.2.2 DETERMINATION OF ACTUAL VALUES OF t
S i n c e a c t u a l c o r e s h e a r modulus v a l u e s a r e n o t v e r y l a r g e , a v a l u e of
t somewhat g r e a t e r t h a n t h a t g i v e n by formula ( 1 9 : l l ) o r (19:12) must be
u s e d . A c t u a l v a l u e s of t c a n be determined from f o r m u l a s ( 1 9 : l l ) o r (19:12)
w i t h v a l u e s of k and k22 r e a d from t h e g r a p h s o f f i g u r e s 19-11 and 19-12
11
f o r W # O . I n u s i n g t h e s e g r a p h s i t i s n e c e s s a r y t o i t e r a t e because W i s
d i r e c t l y p r o p o r t i o n a l t o t . A s a n a i d t o f i n a l l y d e t e r m i n i n g t and Gc f i g u r e
19-6 p r e s e n t s a number of l i n e s r e p r e s e n t i n g V o r W f o r v a r i o u s v a l u e s of
G, w i t h V o r W r a n g i n g from 0.01 t o 2 and Gc r a n g i n g from 1,000 t o 1,000,000
p s i . The f o l l o w i n g procedure i s s u g g e s t e d :
1. Determine kll and k22 from f i g u r e s 1 9 - 1 1 and 19-12 u s i n g a v a l u e
of 1 f o r W.
2. Compute t a s t h e l a r g e r of f o r m u l a s ( 1 9 : l l ) o r (19:12).
3. Compute t h e c o n s t a n t r e l a t i n g W t o Gc
-
tG = WGc
2b
4. With t h i s c o n s t a n t e n t e r f i g u r e 19-6 and d e t e r m i n e n e c e s s a r y G c .
5. I f t h e s h e a r modulus i s o u t s i d e t h e range of v a l u e s f o r m a t e r i a l s
a v a i l a b l e , s l i d e up t h e a p p r o p r i a t e l i n e of f i g u r e 19-6 and p i c k a new
v a l u e f o r W , f o r a r e a s o n a b l e v a l u e of c o r e s h e a r modulus.
6 . R e e n t e r f i g u r e s 19-11 and 19-12 w i t h t h e new v a l u e of W and

r e p e a t p r e v i o u s s t e p s 1 t h r o u g h 5.
19-6
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19.2.2.3 CHECKING PROCEDURE FOR SANDWICH

STRIPS OF TRIANGULAR CROSS SECTION
The d e s i g n s h a l l b e checked by u s i n g t h e g r a p h s of f i g u r e s 1 9 - 1 1 t o
19-13 t o d e t e r m i n e t h e k c o e f f i c i e n t s and f o r m u l a s ( 1 9 : 7 ) , ( 1 9 : 9 ) and
(19:lO) t o d e t e r m i n e t h e o r e t i c a l performance.
I f t h e t r i a n g u l a r c r o s s s e c t i o n i s e n c l o s e d t h e a n g l e of t w i s t c a n
be d e t e r m i n e d by t h e o r y of R e f e r e n c e ( 1 9 - 2 ) . The c o e f f i c i e n t k l l f o r
enclosed, t h i n - w a l l e d , t r i a n g u l a r c r o s s s e c t i o n s i s given i n t h e graph
of f i g u r e 19-14.
(19-1) MONTREY, HENRY M . , AND KUENZI, EDWARD W.

1973. Design P a r a m e t e r s f o r T o r s i o n of Sandwich S t r i p s Having
T r a p e z o i d a l , R e c t a n g u l a r , and T r i a n g u l a r C r o s s S e c t i o n s .
U.S. F o r e s t S e r v . Res. Pap. FPL 156. F o r e s t P r o d . L a b . ,
Madison, W i s .
(19-2) MCCOMB, HARVEY G . , J R .

1956. T o r s i o n a l S t i f f n e s s of Thin-Walled S h e l l s Having Rein-
f o r c i n g Cores and R e c t a n g u l a r , T r i a n g u l a r , o r Diamond
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
C r o s s S e c t i o n . NACA TN 3749.
19-7

MIL-HDBK-23A
24 A p r i l 1974
-t
L
Figure 19-l.--Notation for sandwich of trapezoidal cross section in t o r s i o n .
19-8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

____-
MIL-HDBK-23A CHG N O T I C E 3 = 9999970 OLq309 049 =

MIL-HDBK-23A
24 April 1974
2.4 - I I
O
e=-
k, TL R = # TAN a
2fb2G
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 0.02 0.04 0.06 0.08 o./o
Figure 19-2.--Coefficient k f o r designing sandwich

1
of rectangular and trapezoidal cross section--
stiff cores.
(M 141 398)
19-9

_ _ _ ~
MIL-HDBK-23A
24 A p r i l 1974
O 0.4 O.8 /.2 /.6 2.0
F i g u r e 19-3 .--Coefficient k f o r designing sandwich

1
of r e c t a n g u l a r and t r a p e z o i d a l c r o s s s e c t i o n .
(M 141 399)
19-10
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

__-__- ___.
MIL-HDBK-23A CHG N O T I C E 3 m 9999970 O L V 8 3 L l 7T7 m
MIL-HDBK-23A
24 April 1974
--- EXTRA
I
POLA TED
I
0.1
o.2
0.3
O.4
0.5
k
I
3
4
5
IO
O a02 0.04 0.06 008 0:IO

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Figure 19-4.--Coefficient k f o r d e s i g n i n g sandwich

2
of r e c t a n g u l a r and t r a p e z o i d a l c r o s s s e c t i o n - -
s t i f f cores.
(M 141 400)
19 -11

~~~
MIL-HDBK-23A CHG N O T I C E 3 = 7%79770 OL48312 6 3 3
MIL-HDBK-23A
24 A p r i l 1974
46
O
0.05
1.4
o. /
o. 2
1.2
O.3
O.4
40 O.5
I I I I I I
O 0.4 0.8 1.2 /.6 20
Figure 19-5.--Coefficient k2 for designing sandwich

of r e c t a n g u l a r and t r a p e z o i d a l c r o s s section.
(M 141 401)
19 -12
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

--
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
I-
MIL -HDBK-2 3A
24 A p r i l 1974
19 -13

= 9999970 0348334
~-
MIL-HDBK-23A
24 A p r i l 1974
2.4 I I I I l 1
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
F i g u r e 19-7.--Coefficient k 3 for designing sandwich

of rectangular and tra?ezoidal cross section--
stiff c o r e s .
(21 141 4 0 7 )
1 9 -14

-___ ____
MIL-HDBK-23A CHG N O T I C E 3 9 7 9 7 9 7 0 OL483L.5 3 4 2
MIL-HDBK-23A
24 A p r i l 1974
.L3
T
O
O 0.4 0.8 l.2 l.6 2-0
Figure 19-8.--Coeff i c i e n t k3 f o r d e s i g n i n g sandwich

of r e c t a n g u l a r and t r a p e z o i d a l c r o s s s e c t i o n .
-.
19-15
(M 141 402)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HDBK-23A CHG N O T I C E 3 9977970 Ol1483Lb 2 8 9
MIL -WBK-2 3A
24 A p r i l 1974
44
O 00.2 0.04 0.06 a08 o./O o./4

l/=thG -
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Zb2Gc
Figure 19-9.--Coefficient k f o r d e s i g n i n g sandwich

1
s t r i p s of e n c l o s e d , t h i n - w a l l e d , rectangular cross
section i n torsion.
(M 141 4 0 3 )
19-16
_ _ _ _ _ _ m

-~ - _ _ _____-__
MIL-HDBY-23A CYG N O T I C E 3 W 9999970 0348337 3 3 5
MIL -HDBK-z3A
24 April 1974
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
i-
/
?t-=-
;------; -,i
I I I
Figure 19-10.--Notation f o r sandwich of triangular cross section in

tor si on.
19-17

-
MIL-HDBK-23A C H G N O T I C E 3 M 9999970 O L 4 3 L B 051
MIL -HDBK- 23A

24 A p r i l 1974
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
O 5 /O 20 25 35
Figure 19-ll.--Coefficient k for designing sandwich

11
s t r i p s of triangular cross section in torsion.
19 -18
(M 141 404)

MIL-HDBK-23A CHG N O T I C E 3 W 9997970 0 3 4 8 3 3 9 T 9 8 W
M I L -HDBK-2 3 A
2 4 A p r i l 1974
/O
2~
O
O
I.- 5 /O /5 20 25 30 35
W = tG-
2bGc
19-19
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

MIL-HDBK-23A CHG N O T I C E 3 9 9 9 9 9 7 0 0 3 4 8 3 2 0 70T
MIL-HDBK-23A
24 April 1974
'7
O 5 /O 15 20 25 30 35
F i g u r e 19-13 . - - C o e f f i c i e n t kf o r d e s i g n i n g sandwich
33
s t r i p s of t r i a n g u l a r c r o s s s e c t i o n i n t o r s i o n .
(M 141 405) 19-20
.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

NIL-HDBK-23A CHG N O T I C E 3 ~ q ~ 0148321
~ ~ 7646
0
MIL -HDBK-23A
24 A p r i l 1974
3500
3000
2500
2000
s
t
1500
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
1000
500
O
O 4 8 /2 16 20 24
w=- 1G
266,
Figure 19-14.--Coefficient k 11 for designing sandwich

strips of t r i a n g u l a r c r o s s s e c t i o n i n t o r s i o n .
19 -2 1
(M 141 406)
U. S. GOVERNUENT PRINTING OFFICE 1974-713-167/1764
__

MIL -HDBK -2 3 A
19 June 1974
CHAPTER 20 -- DESIGN OF CIRCULAR
SANDWICH PANELS LOADED AT AN INSERT
Page
20.1 Scope 20-1
20.2 Basic Principles 20-1
20.3 Determining Insert Size 20-2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-- -~~
-~
--___
MIL-HDBK-23A
19 June 1974
CHAPTER 20
DESIGN OF FLAT CIRCULAR SANDWICH PANELS
LOADED AT AN INSERT
20.1 SCOPE
This chapter p r e s e n t s information f o r t h e design of a sandwich panel

with a . r i g i d i n s e r t . The i n s e r t i s placed i n t h e sandwich panel t o allow
t h e i n t r o d u c t i o n of load from a p o i n t o u t s i d e t h e plane of t h e panel. The
b a s i c formulas f o r d e f l e c t i o n s and s t r e s s e s ( r e f . 20-1) were derived f o r a
load normal t o t h e panel. Experimental d a t a ( r e f . 20-3), however, have shown
t h a t t h e formulas were a l s o s a t i s f a c t o r y f o r loads i n c l i n e d a t angles between
45' and 90' t o t h e panel plane provided t h a t t h e formulas were modified t o
u t i l i z e t h e normal component of t h e i n c l i n e d load. Deflections a t t h e i n s e r t
and stresses i n t h e neighborhood of t h e i n s e r t a r e t h e bases f o r design.
Although t h e design formulas were derived f o r c i r c u l a r panels, t h e i r

a p p l i c a t i o n t o panels of o t h e r shapes would not be expected t o be i n g r e a t
e r r o r i f t h e i n s e r t s i z e was r e l a t i v e l y small compared with t h e panel s i z e .
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Usually t h e design of a sandwich panel with an i n s e r t w i l l begin with

a panel configuration based upon in-plane o r normal d i s t r i b u t e d loading as
covered by o t h e r chapters i n t h i s handbook, thus r e s u l t i n g i n known facing
and c o r e thicknesses and core shear p r o p e r t i e s . An i n s e r t i s then t o be
placed i n t h e panel t o allow i n t r o d u c t i o n of load, and t h e s i z e of t h e i n s e r t
must be determined p l u s t h e stresses and d e f l e c t i o n s caused by t h e load applied
a t t h e i n s e r t . The procedure followed here w i l l be t o determine i n s e r t s i z e
based on core shear stress l i m i t a t i o n s and then check facing s t r e s s e s and
sandwich d e f l e c t i o n s .
Assuming t h a t a design begins with chosen design s t r e s s e s and a given

load t o transmit, a sandwich panel with a loaded i n s e r t s h a l l be designed
t o comply with t h e four b a s i c design p r i n c i p l e s summarized i n 1 . 2 of Intro-
duction. These f o u r conditions must be met.
20- 1

-.- -- .____- - -
MIL-HDBK-23A CHG N O T I C E 3 m 9 9 9 9 9 7 0 O348324 355 m
MIL-HDBK-23A
19 June 1974
Detailed procedures giving t h e o r e t i c a l formulas and graphs f o r determining

i n s e r t s i z e , facing stresses, and panel d e f l e c t i o n s are given i n t h e following
paragraphs. Where double formulas are given, one formula i s f o r sandwich with
facings of d i f f e r e n t materials and thicknesses and a second formula i s f o r sand-
wich with each facing of t h e same material and thickness. Facing and core
e l a s t i c p r o p e r t i e s and s t r e s s e s s h a l l be values a t t h e condition of use; t h a t
i s , i f a p p l i c a t i o n i s a t elevated temperature then p r o p e r t i e s a t elevated tempera-
t u r e s h a l l be used i n design. The following procedures are r e s t r i c t e d t o l i n e a r
elastic behavior.
20.3 DETERMINING INSERT SIZE
This s e c t i o n gives t h e procedure f o r determining t h e i n s e r t diameter

s o t h a t t h e shear s t r e s s i n t h e sandwich core w i l l not exceed allowable values.
The core shear stress i s given by t h e t h e o r e t i c a l formula ( r e f . 20-1):
(20: 1)
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
where P i s t h e normal component of t h e load applied a t t h e i n s e r t , h i s distance
between facing centroids, b i s i n s e r t radius, and k r i s a c o e f f i c i e n t dependent
upon b/a and @I where-
(20: 2)
where a i s r a d i u s of c i r c u l a r sandwich p l a t e , Gc i s core shear modulus and
DF -- 6x
't3 ( f o r equal facings) (20: 3a)
where E i s modulus of e l a s t i c i t y of facing; X = 1 y'; y i s f a c i n g -

Poisson's r a t i o ; t i s facing thickness; and 1 and 2 are s u b s c r i p t s denoting
facing 1 o r 2.
20- 2

MIL-HDBK- 23A
19 J u n e 1974
The r a d i a l d i s t r i b u t i o n o f t h e c o r e s h e a r stress c o e f f i c i e n t k r i s
shown i n f i g u r e 20-1 f o r a p a n e l i n which b / a = 0.04. The maximum s h e a r
stress c o e f f i c i e n t o c c u r s n e a r t h e i n s e r t f o r l a r g e v a l u e s o f (@a) and
moves away from t h e i n s e r t and becomes smaller as v a l u e s o f (@a) d e c r e a s e .
T h e r e f o r e , it i s n o t wise t o u s e a s t i f f c o r e i f s h e a r stresses approach
design allowables i n f a i r l y large panels.
The maximum c o r e s h e a r stress upon which t h e d e s i g n must b e based

i s g i v e n by t h e f o r m u l a ( r e f . 20-1)
F = -k3P (20:4)
scmax 2rhb
where kg i s g i v e n i n t h e graph of f i g u r e 20-2. S o l v i n g formula (20:4) f o r

b results in
S
b = (20:s)
mFscmax
S o l u t i o n o f f o r m u l a ( 2 0 : s ) c a n n o t b e performed d i r e c t l y b e c a u s e t h e
c o e f f i c i e n t k3 i s dependent upon v a l u e s o f b as g i v e n i n t h e a b s c i s s a ,
b / a , o f f i g u r e 20-2. A means o f i n d i r e c t s o l u t i o n o f (20:s) can b e
d e v i s e d as f o l l o w s : S o l v i n g ( 2 0 : s ) f o r k3 i n terms o f b / a r e s u l t s i n
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
k
3
= C )(: (20: 6)
where
2rhaFscmax
C = (20:7 )
P
Formula (20:6) r e p r e s e n t s a f a m i l y o f s t r a i g h t l i n e s h a v i n g a s l o p e , C ,
and e x t e n d i n g from t h e o r i g i n o f t h e graph o f f i g u r e 20-2. The v a l u e of
C i s d e t e r m i n e d from f o r m u l a (20:7) w i t h known d i m e n s i o n s , stress, and
l o a d . A s o l u t i o n o f (20:s) i s o b t a i n e d from t h e i n t e r s e c t i o n o f a s t r a i g h t
l i n e o f s l o p e C w i t h t h e a p p r o p r i a t e $a c u r v e on t h e graph o f f i g u r e 20-2.
The v a l u e o f t h e i n s e r t r a d i u s , b , i s o b t a i n e d by m u l t i p l y i n g t h e a b s c i s s a
o f t h e i n t e r s e c t i o n p o i n t by t h e p a n e l r a d i u s , a . T h i s can b e checked by
r e a d i n g k3 a t t h e i n t e r s e c t i o n p o i n t and s u b s t i t u t i o n i n t o f o r m u l a ( 2 0 : s ) .
Examples i l l u s t r a t i n g p r o c e d u r e w i l l f o l l o w f a c i n g stress and p a n e l
deflection determinations.
20-3

~ _ _ - - ~ . _ _ _ _
mIL-HDBK-23A CHG N O T I C E 3 m 9999970 0148326 128 m
MIL-HDBK-23A
1 9 J u n e 1974
The maximum f a c i n g stress o c c u r s a t t h e i n s e r t i n t h e r a d i a l

d i r e c t i o n and i s g i v e n by t h e f o r m u l a
( 2 0 : 8)
w h e r e F 1 2 i s s t r e s s i n f a c i n g 1 o r 2 of t h i c k n e s s e s t l o r t 2 and k4 i s
g i v e n by t h e g r a p h of f i g u r e 20-3. Curves are g i v e n , i n f i g u r e 20-3, f o r
p a n e l s w i t h o u t e r r i m s i m p l y s u p p o r t e d o r clamped.
The d e f l e c t i o n a t t h e i n s e r t i s g i v e n i n two p a r t s , bending d e f l e c -

t i o n , bg; and s h e a r d e f l e c t i o n , S. The bending d e f l e c t i o n i s g i v e n by
t h e formula
klPa 2
g =- (20:9)
B 16~D
where k l i s g i v e n by t h e graph o f f i g u r e 20-4 f o r p a n e l s w i t h o u t e r r i m

s i m p l y s u p p o r t e d o r clamped; and D i s sandwich bending s t i f f n e s s g i v e n
by
E t E t h 2
D = 1 1 2 2 ( 2 0 : 10)
+E t )
X(Eltl 2 2
D = - Eth2 (20: loa)

2x
The s h e a r d e f l e c t i o n a t t h e i n s e r t i s g i v e n by t h e formula
g =- L
s 2.rrhGc (20: 11)
where k2 i s g i v e n by t h e graph o f f i g u r e 20-5.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
20-4
--
Provided by IHS
-- .
MIL-HDBK-23A C H G N O T I C E 3 W 9797970 0348327 Ob4 W
MIL-HDBK- 23A
19 J u n e 1974
Examples :
1. A sandwich h a s 0.080-inch f a c i n g s on a c o r e 1 . 1 2 i n c h t h i c k . The

f a c i n g modulus o f e l a s t i c i t y i s E = 10,000,000 p . s . i . and P o i s s o n ' s
r a t i o i s p = 0.3. The c o r e s h e a r modulus i s Gc = 2,000 p . s . i . and c o r e
s h e a r d e s i g n stress Fsc = 60 p . s . i . The p l a t e h a s a r a d i u s a = 25 i n c h e s
and a n i n s e r t s u p p o r t i n g a normal l o a d component o f 1 , 9 0 0 pounds. D e t e r -
mine t h e i n s e r t s i z e d and f i n a l l y s t r e s s e s and d e f l e c t i o n s .
From f o r m u l a ( 2 0 : 3 a ) DF = 940 pounds i n . 2 / i n . o f w i d t h ; from formula

(20:2) <p a = 40; and from f o r m u l a (20:7) C = 5.95. From f i g u r e 20-2 t h e
i n t e r s e c t i o n of t h e l i n e C = 5 . 9 5 w i t h t h e c u r v e < p a = 40 o c c u r s a t b / a =
0.091 and k3 = 0.54. From t h i s b = 0.091(25) = 2.28 i n c h , t h u s g i v i n g
an i n s e r t d i a m e t e r of 4.56 i n c h e s . Checking by s u b s t i t u t i n g k3 = 0.54
i n t o f o r m u l a ( 2 0 : s ) a l s o produces t h e same i n s e r t s i z e .
From f i g u r e 20-3 it i s d e t e r m i n e d t h a t k4 = 5 . 2 6 f o r t h e r i m s i m p l y
s u p p o r t e d ; s u b s t i t u t i o n o f t h i s i n t o forumla (20:8) r e s u l t s i n a f a c i n g
stress o f 8,280 p . s . i .
From f o r m u l a (20:lOa t h e sandwich bending s t i f f n e s s i s found t o b e

D = 633,000 pounds i n . i l i n . of w i d t h . From t h e graph o f f i g u r e 20-4
it i s d e t e r m i n e d t h a t k l = 2.16 f o r t h e r i m s i m p l y s u p p o r t e d and sub-
s t i t u t i o n of t h i s i n t o f o r m u l a (20:9) r e s u l t s i n a bending d e f l e c t i o n of
0.081 i n c h . From f i g u r e 20-5, k2 = 2 . 1 5 and s u b s t i t u t i o n i n t o f o r m u l a
( 2 0 : l l ) r e s u l t s i n a s h e a r d e f l e c t i o n o f 0.271 i n c h . Thus t h e t o t a l i n s e r t
d e f l e c t i o n was 0.352 i n c h .
2. A sandwich t h e same s i z e as t h e p r e v i o u s example w i t h t h e same

material i n t h e f a c i n g s b u t a c o r e 10 times stiff--Gc = 20,000 p . s . i . and
s t r e n g t h o f Fsc = 300 p . s . i . For t h e s e d a t a v a l u e s o f a = 126 and C =
29.8 and from f i g u r e 20-2 t h e r e i s no s o l u t i o n . A c o n s e r v a t i v e s o l u t i o n
can be made by assuming k3 = 1. Then from formula ( 2 0 : s ) b = 0.84 i n c h ,
t h u s g i v i n g an i n s e r t d i a m e t e r of 1 . 6 8 i n c h . P r o c e e d i n g as i n t h e p r e v i o u s
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
example w e d e t e r m i n e :
F a c i n g stress F = 11,460 p . s . i
Bending d e f l e c t i o n 6~ = 0.090 i n c h
S h e a r d e f l e c t i o n 6, = 0.044 i n c h
Total deflection = 0.134 i n c h
20-5

_ _
=
-
_.__ ~
MIL-HBBK-23A CHG N O T I C E 3 9999970 0148328 T T O
MIL-HDBK-23A
19 June 1974
(20-1) MONTREY, HENRY M.

1973. Bending of a C i r c u l a r Sandwich P l a t e by Load Applied
Through an I n s e r t . USDA Forest Serv. Res. Pap.
FPL 201. Forest Prod. Lab., Madison, Wis.

Current. Metallic Materials and Elements f o r Aerospace
Vehicles Structures. M i l i t a r y Handbook 5.
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
Available from U.S. Gov. P r i n t . Office,
Washington, D.C.
(20-3) YOUNGQUIST, W.G., AND KUENZI, EDWARD W.

1955-56. S t r e s s e s Induced i n a Sandwich Panel by Load Applied
a t an I n s e r t . U.S. Forest Prod. Lab. Reps. 1845,
1845A, and 1845B.
20-6

-- ~-
-
MSL-HDBK-23A CHG N O T I C E 3 m 9999970 0348329 937 m
MIL-HDBK- 23A
19 June 1974
/.O
0.8
0.6
0.4
o.2
U
o o.2 o. 4 O.6 O.8 I. o
M 141 662
Figure 2 0 - 1 , --Radial distribution of core ghear s t r e s s coefficient k,.

R i m of panel simply supported.
...
20-7
---
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---

-
MIL-HBBK-23A CHG N O T I C E 3 = 9999970 0 3 4 8 3 3 0 -
659
MI L- HDBK- 2 3A
19 June 1974
O.9
I /. --I
80
0.8
40
o. 7
O.6 20
o.Y 12
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
k,
.t
8 B
O.4 '8.
O.3
4
3
o.2
2
o. /
/
O
O 3.04 0.08 o.i2 O.16 0.20 0.24
-
b
O
Figure 20-2. --Coefficient k3 for determining maximum core shear

s t r e s s ; rim simply supported. (For a clamped r i m k3 values are
conservative for ga < 6 . ) (M 141 6 5 9 )
___ 20-8

__ ___
NIL-HDBK-23A C H G N O T I C E 3 9 9 7 9 9 7 0 O L 4 3 3 L 595 W
MI L-HDBK- 2 3A
19 June 1974
8
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
P
.L
O
O 0.04 0.08 o.12 0./6 0.20 0.24
Figure 20-3. --Coefficient k4 for determining maximum facing streor.

M 141 661
20-9
-

--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
MIL-HDBK- 23A
19 June 1974
M 141 660
Figure 20-4 c -- Coefficient k l for determining bending deflection at

insert.
20-10
._.

____- --
MIL-HDBK-23A
~~
CHG NOTICE 3 9999970 0348333 368
MIL-HDBK- 23A
19 June 1974
3.s'
3.2
%8
24
2.o
1.6
80
/. 2 FI- 40
20
/2
--`,,`,,,`,,,`,```,,`,,,``,``,`-`-`,,`,,`,`,,`---
8
6
0.8
4 o
'8.
3
O.4 2
O
O 0.04 O.08 o. /a? O.16 o.20 O.24
Figure 20-5. --Coefficient k2 for determining rhear deflection at insert,

.rim dmply rupported. (For a clamped r i m k2 valueo are canrervative
for $a < 8. ) (M i41 658)
US. GOVERNMENT PRINTING OFFICE: 1974-605121:218
--- -- _ _ $0-11
-y __
- -- -


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MILITARY S-TANDARDIZATION HANDBOOK

STRXTURAL SANDWICH COMPOSITES

TO ALL HOLDERS OF MIL-HDBK-23A

1. On t h e second page of t h e Table of C o n t e n t s under C h a p t e r 4 , d e l e t e t h e

P a r a g r a p h Number New Page Number

2 . D e l e t e p a g e s 4 - 1 t h r u 4-8 d a t e d 30 December 1968 and s u b s t i t u t e t h e

C o n t e n t s Page f o r 1 9 June 1974

4-1 t h r u 4-5 19 June 1974

C o n t e n t s Page f o r 19 June 1974

20-1 t h r u 20-6 19 June 1974

3. RETAIN THIS NOTICE AND INSERT BEFORE THE TABLE OF CONTENTS.

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MIL-HDBK-23A CHG N O T I C E 3 m 7 0 0347845 7T7

MILITARY STANDARDIZATION HANDBOOK

1. THE FOLLOWING PAGES ARE TO BE. ADDED:

NEW PAGES DATE

2. RETAIN THIS NOTICE AND INSERT BEFORE THE TABLE OF CONTENTS.

3 . Holders of MIL-HDBK-23A w i l l v e r i f y t h a t t h e a d d i t i o n of Chapter 1 9

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MILITARY STANDARDIZATION HANDBOOK

STRUCTURAL SANDWICH COMPOSITES

TO ALL HOLDERS OF MIL-HDBK-23A

Paragraph No. New Page No.

2 . THE FOLLOWING PAGES OF MIL-HDBK-23A HAVE BEEN REVISED AND SUPERSEDE

NEW PAGES DATE SUPERSEDED DATE

9-1 t h r u 9-13 9 Mar 1972 9-1 t h r u 9-11 30 Dec 1968

9-14 t h r u 9-39 9 Mar 1972 F i g u r e s 9-1 t h r u 30 Dec 1968

2. THE FOLLOWING PAGES ARE TO BE ADDED:

NEW PAGES DATE

Contents Page f o r 9 Mar 1972

18-1 t h r u 18-14 9 Mar 1972

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3. RETAIN THIS NOTICE AND INSERT BEFORE THE TABLE OF CONTENTS.

4. Holders of MIL-KDBK-23A w i l l v e r i f y t h a t page changes and additions

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STRUCTURAL SANDWICH COMPOSITES

1. T h i s s t a n d a r d i z a t i o n handbook h a s been developed and i s being maintained

2. T h e i n f o r m a t i o n contained i n t h i s publication h a s been obtained f r o m n u m e r -

3 . E v e r y effort h a s been m a d e t o r e f l e c t the l a t e s t information on design,

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1. Scope. ................... 0 0 0 0 . 0 1-1

1.3 Fundamental F o r m u l a s o e e 0 0 a 1-4

1.3.2 Sandwich Extensional Stiffness e a s . 0 0 . 1-6

2.1 Facing M a t e r i a l s . .... . e e e e ...... ... o o 2-1

2.3.1 Types 2-18

2.3.2 Available S o u r c e s . . .. 2 -24

2 . 3 . 4 S t o r a g e and Mixing of Adhesives , 2-25

2.3.5 Strength of Adhesive Bonds o o o o o o e e 2 -26

UNDER EDGEWISE LOAD

3.1 B a s i c P r i n c i p l e s . e o.. e o .o a a e o . . . e e e e 3-1

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CHAPTER 4--DIMPLING O F SANDWICH FACINGS

UNDER EDGEWISE LOAD

4.1 Basic Principles. ............... 4-1

4.2 Sandwich Having C e l l u l a r (Honeycomb) C o r e 4-1

CHAPTER 5--DESIGN O F F L A T RECTANGULAR S, NDWICH P. r ELS

UNDER EDGEWISE COMPRESSION LOAD

5.1 B a s i c P r i n c i p l e s . .................... 5-1

5.3.3 Checking P r o c e d u r e f o r Determining Buckling S t r e s s ,

CHAPTER 6 . --DESIGN O F F L A T RECTANGULAR SANDWICH PANELS

UNDER EDGEWISE SHEAR LOAD